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“EMERGENCY COIN OPERATED MOBILE BATTERY CHARGER” CHAPTER 1 PLAN OF WORK Weekly work P.V.POLYTECHNIC, S.N.D.T. University, Mumbai-049. Page | 1

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Page 1: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 1

PLAN OF WORK

Weekly work

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

11 WEEKLY WORK

1st week Project Name selection

1st week Literature Survey

1st week Problem Definition

2nd week Block diagram

3rd to 5th week Details of individual block

6th week Rough circuit diagram

7th week Availability of parts in market

8th week Purchasing parts

8th week Testing individual Parts

8th week Finalizing circuit diagram

9th week PCB designing

9th amp10th week Soldering of parts

11th week Testing amp troubleshooting each module

12th week Complete testing of final circuit

13th week Writing individual module of software

14th amp15th week Final testing of software module

16th week Final testing of hardware amp software

17th week Finishing final project

17th amp18th week Report preparation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 2

Table 11 Table for Weekly work

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 2

INTRODUCTION

Introduction Functional descriptionTechnology used

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

21 Introduction

With mobile phones becoming the major source of businesspersonal

communication the mobile phone business is currently worth billions of dollars and

supports millions of phones

The need to provide a public charging service is essential Many critics argued that a

public mobile phone charging service is not a lucrative business because most users can

charge their phones at home in their office or in their cars

Emergency Coin Operated Mobile Phone Charger is a new business milestone

because many are attending business conventions and forgetting their charger at home or in

hotel rooms

Students and many that use the public transportation that dont know that their level

of their battery is low are prospective customers for coin operated mobile phone charger

service

Recommended locations include Hotels conference centers exhibition halls

serviced offices exchange halls motels leisure centers health clubs training centers golf

clubs retail outlets shopping malls Internet cafes universities colleges hall of residence

airports train terminals etc so that the mobile phone users can reactivate a low or dead

battery by simply plugging in and charging for as low as one rupees

22 Functional description

The coin operated public cell phone charger is a cell phone charging station having

four charging channels providing charging facility to various type of cell phones The

number of channels can be increased further Each channel can be operated simultaneously

Each and every channel is having a select switch which can be called as channel

select switch with a red LED as an indicator for selected channel Also there is a START

switch and a COIN inlet which is common for all the channels

The operation of coin operated chargers is very simple The user who wishes to

charge his cell phone has to first check out for the compatible charger jack in a channel

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Then he has to press select switch in order to make channel ready for charging the

selected channel will be indicated by a red LED

The channel will remain in selected mode for 30 sec Hence within 30 sec the user

has to first insert the predefined rupee coin and then has to press START switch which will

finally start the charging process for a predefined time and is indicated by a green LED

If failing to do so within 1 min will reset the channel and the user has to again

follow the same procedure

Any other channel selection is not considered within 30 sec of previous channel if

selected or until it has entered in to charging mode

Completion of charging will be indicated by an OFF green LED

23 Technology Used

Coin recognition using proximity switch(metal detector)

Constant voltage charger

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 3

DEVELOPMENT

STAGES amp

PROCESS

Development stages and process of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 2: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

11 WEEKLY WORK

1st week Project Name selection

1st week Literature Survey

1st week Problem Definition

2nd week Block diagram

3rd to 5th week Details of individual block

6th week Rough circuit diagram

7th week Availability of parts in market

8th week Purchasing parts

8th week Testing individual Parts

8th week Finalizing circuit diagram

9th week PCB designing

9th amp10th week Soldering of parts

11th week Testing amp troubleshooting each module

12th week Complete testing of final circuit

13th week Writing individual module of software

14th amp15th week Final testing of software module

16th week Final testing of hardware amp software

17th week Finishing final project

17th amp18th week Report preparation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 2

Table 11 Table for Weekly work

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 2

INTRODUCTION

Introduction Functional descriptionTechnology used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

21 Introduction

With mobile phones becoming the major source of businesspersonal

communication the mobile phone business is currently worth billions of dollars and

supports millions of phones

The need to provide a public charging service is essential Many critics argued that a

public mobile phone charging service is not a lucrative business because most users can

charge their phones at home in their office or in their cars

Emergency Coin Operated Mobile Phone Charger is a new business milestone

because many are attending business conventions and forgetting their charger at home or in

hotel rooms

Students and many that use the public transportation that dont know that their level

of their battery is low are prospective customers for coin operated mobile phone charger

service

Recommended locations include Hotels conference centers exhibition halls

serviced offices exchange halls motels leisure centers health clubs training centers golf

clubs retail outlets shopping malls Internet cafes universities colleges hall of residence

airports train terminals etc so that the mobile phone users can reactivate a low or dead

battery by simply plugging in and charging for as low as one rupees

22 Functional description

The coin operated public cell phone charger is a cell phone charging station having

four charging channels providing charging facility to various type of cell phones The

number of channels can be increased further Each channel can be operated simultaneously

Each and every channel is having a select switch which can be called as channel

select switch with a red LED as an indicator for selected channel Also there is a START

switch and a COIN inlet which is common for all the channels

The operation of coin operated chargers is very simple The user who wishes to

charge his cell phone has to first check out for the compatible charger jack in a channel

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Then he has to press select switch in order to make channel ready for charging the

selected channel will be indicated by a red LED

The channel will remain in selected mode for 30 sec Hence within 30 sec the user

has to first insert the predefined rupee coin and then has to press START switch which will

finally start the charging process for a predefined time and is indicated by a green LED

If failing to do so within 1 min will reset the channel and the user has to again

follow the same procedure

Any other channel selection is not considered within 30 sec of previous channel if

selected or until it has entered in to charging mode

Completion of charging will be indicated by an OFF green LED

23 Technology Used

Coin recognition using proximity switch(metal detector)

Constant voltage charger

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 3

DEVELOPMENT

STAGES amp

PROCESS

Development stages and process of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 3: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 2

INTRODUCTION

Introduction Functional descriptionTechnology used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

21 Introduction

With mobile phones becoming the major source of businesspersonal

communication the mobile phone business is currently worth billions of dollars and

supports millions of phones

The need to provide a public charging service is essential Many critics argued that a

public mobile phone charging service is not a lucrative business because most users can

charge their phones at home in their office or in their cars

Emergency Coin Operated Mobile Phone Charger is a new business milestone

because many are attending business conventions and forgetting their charger at home or in

hotel rooms

Students and many that use the public transportation that dont know that their level

of their battery is low are prospective customers for coin operated mobile phone charger

service

Recommended locations include Hotels conference centers exhibition halls

serviced offices exchange halls motels leisure centers health clubs training centers golf

clubs retail outlets shopping malls Internet cafes universities colleges hall of residence

airports train terminals etc so that the mobile phone users can reactivate a low or dead

battery by simply plugging in and charging for as low as one rupees

22 Functional description

The coin operated public cell phone charger is a cell phone charging station having

four charging channels providing charging facility to various type of cell phones The

number of channels can be increased further Each channel can be operated simultaneously

Each and every channel is having a select switch which can be called as channel

select switch with a red LED as an indicator for selected channel Also there is a START

switch and a COIN inlet which is common for all the channels

The operation of coin operated chargers is very simple The user who wishes to

charge his cell phone has to first check out for the compatible charger jack in a channel

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Then he has to press select switch in order to make channel ready for charging the

selected channel will be indicated by a red LED

The channel will remain in selected mode for 30 sec Hence within 30 sec the user

has to first insert the predefined rupee coin and then has to press START switch which will

finally start the charging process for a predefined time and is indicated by a green LED

If failing to do so within 1 min will reset the channel and the user has to again

follow the same procedure

Any other channel selection is not considered within 30 sec of previous channel if

selected or until it has entered in to charging mode

Completion of charging will be indicated by an OFF green LED

23 Technology Used

Coin recognition using proximity switch(metal detector)

Constant voltage charger

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 3

DEVELOPMENT

STAGES amp

PROCESS

Development stages and process of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 4: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

21 Introduction

With mobile phones becoming the major source of businesspersonal

communication the mobile phone business is currently worth billions of dollars and

supports millions of phones

The need to provide a public charging service is essential Many critics argued that a

public mobile phone charging service is not a lucrative business because most users can

charge their phones at home in their office or in their cars

Emergency Coin Operated Mobile Phone Charger is a new business milestone

because many are attending business conventions and forgetting their charger at home or in

hotel rooms

Students and many that use the public transportation that dont know that their level

of their battery is low are prospective customers for coin operated mobile phone charger

service

Recommended locations include Hotels conference centers exhibition halls

serviced offices exchange halls motels leisure centers health clubs training centers golf

clubs retail outlets shopping malls Internet cafes universities colleges hall of residence

airports train terminals etc so that the mobile phone users can reactivate a low or dead

battery by simply plugging in and charging for as low as one rupees

22 Functional description

The coin operated public cell phone charger is a cell phone charging station having

four charging channels providing charging facility to various type of cell phones The

number of channels can be increased further Each channel can be operated simultaneously

Each and every channel is having a select switch which can be called as channel

select switch with a red LED as an indicator for selected channel Also there is a START

switch and a COIN inlet which is common for all the channels

The operation of coin operated chargers is very simple The user who wishes to

charge his cell phone has to first check out for the compatible charger jack in a channel

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 4

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Then he has to press select switch in order to make channel ready for charging the

selected channel will be indicated by a red LED

The channel will remain in selected mode for 30 sec Hence within 30 sec the user

has to first insert the predefined rupee coin and then has to press START switch which will

finally start the charging process for a predefined time and is indicated by a green LED

If failing to do so within 1 min will reset the channel and the user has to again

follow the same procedure

Any other channel selection is not considered within 30 sec of previous channel if

selected or until it has entered in to charging mode

Completion of charging will be indicated by an OFF green LED

23 Technology Used

Coin recognition using proximity switch(metal detector)

Constant voltage charger

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 3

DEVELOPMENT

STAGES amp

PROCESS

Development stages and process of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 5: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Then he has to press select switch in order to make channel ready for charging the

selected channel will be indicated by a red LED

The channel will remain in selected mode for 30 sec Hence within 30 sec the user

has to first insert the predefined rupee coin and then has to press START switch which will

finally start the charging process for a predefined time and is indicated by a green LED

If failing to do so within 1 min will reset the channel and the user has to again

follow the same procedure

Any other channel selection is not considered within 30 sec of previous channel if

selected or until it has entered in to charging mode

Completion of charging will be indicated by an OFF green LED

23 Technology Used

Coin recognition using proximity switch(metal detector)

Constant voltage charger

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 3

DEVELOPMENT

STAGES amp

PROCESS

Development stages and process of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 6: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 3

DEVELOPMENT

STAGES amp

PROCESS

Development stages and process of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 6

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 7: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

31 DEVELOPMENT STAGES amp PROCESS

The complete development of this project can be divided into the following stages

Problem definition stage

Designing block diagram

Implementing circuits and components

Developing algorithm for software

Writing actual code for Microcontroller

Compiling the code

Burning the hex file into microcontroller with programmer

Testing and Running

311 Problem definition stage

This is the very first stage to develop any project It actually defines the aim

and the concept of the project At inconvenient times when access to a standard

charger isnt possible The aim of ldquoEmergency coin operated mobile chargerrdquo is

designed to solve this problem The charger operates like a vending machine all a

user has to do is plug the mobile phone into one of the four adapters and insert a

coin the phone will then be given a micro-pulse fast charge in just 10 minutes

312 Designing block diagram

At this stage we have categorized the whole system into different individual

modules These modules (block diagrams) will be helpful in understanding the

concept and working of the integrated system It also simplifies the entire debugging

and testing process

313 Implementing circuits and components

This is the actual implementation of circuit of each block At this stage we

have actually designed each block separately and finally integrated them into the

complete working system

314 Developing for software

To get the logical flow of the software the development of algorithm having

a prominent role So that we have to analyze the complete system and organized the

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 7

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 8: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

algorithm in such a manner that one can understand the complete working of the

software

315 Writing actual code for Microcontroller

After the development of the algorithm and flowchart we have actually

translated them in Embedded C language for Phillips p89v51RD2 Microcontroller so

that it can understand the instructions and run as per our requirement The

instructions are in ANSII C Language

316 Compiling the code

The hand written code on paper was then transferred into computer For that

we have used Keil pre-install on PC The Keil is a Computer Aided Program to

simulate the working of Microcontroller in real time without burning the software

into actual IC We simulated and compiled our program for error checking After

removing several compiling errors the program was converted into machine language

ie Philips hex format

317 Burning the hex file into microcontroller with Programmer

In this stage the compiled hex format file was downloaded or burned into

flash Phillips p89v51RD2 Microcontroller This was done by using the Philips in-

system programming software provided by the manufacturer itself

318 Testing and Running

This time we tested our project for actual working after loading the Software

into the microcontroller Any errors found were removed successfully This is the last

and final stage of development of our project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 9: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 4

BLOCK DIAGRAM

OF THE PROJECT

Block Diagram Brief Explanation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 9

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 10: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

41 Block Diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 10

Fig 41 Block diagram of the project

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 11: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

42 Brief Explanation

421 POWER SUPPLY

Power supply is used to deliver power to the circuit It delivers +5Vdc to

microcontroller and other peripherals and +12Vdc delivers power to relay

422 COIN INPUT AND LEVEL CONVERTOR

Coin input is a sensor which senses a metal and produces an output voltage This

voltage is high as compared to the input required for microcontroller

Hence a level shifter is used to bring down the voltage level which could be

readable to microcontroller

423 START SWITCH

Start switch is used to start the charging process of a

mobile phone

424 RS232 INTERFACING TO PC

RS 232 is a protocol used for communication between

computer and microcontroller It is also used for

programming the microcontroller in its ISP (in system

programming) mode

425 CHANNEL READY INDICATOR

It provides visual indication for the channel which is in

charging mode

426 DARLINGTON PAIR ARRAY

Darlington pair array is used as a relay driver

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 11

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 12: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

427 CHANNEL IN CHARGE INDICATION

It provides visual indication for the channel which is in

charging mode

428 RELAY ARRAY

Relay array consists of relays for each channel to

provide electromechanical switching in between charger and

mobile phone

429 CHARGER ARRAY

Charger array is used to provide charging power to the

mobile phones through the electromechanical switches

4210 CELL PHONE TO CHARGE

Channel select switch is used for selecting a channel on

which the mobile phone is to be charged

4211 MICROCONTROLLER

Microcontroller is used to control the whole operation of

the device Microcontroller reads input signal from input

device and triggers the output device According to the

conditions defined in the microcontroller by the programmer

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 12

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 13: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 5

CIRCUIT

DIAGRAM

EXPLANATION

Circuit diagram

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 13

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 14: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Circuit diagram explanation Working

51 POWER SUPPLY CIRCUIT

511 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 14

Fig51 Circuit diagram of the power supply

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 15: automatic coin operated mobile batery charger

Bridge RectifierTRANSFORMER

Filter Voltage regulator Load

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

512 WORKING

Transformer

A step-down transformer is used to achieve our requirements of the power

supply It steps down high voltage ac mains to low voltage ac mains

Bridge Rectifier

A bridge rectifier makes use four diodes in a bridge arrangement to achieve

full wave rectification This is a widely used configuration both with individual

diodes wired and with single component bridges where the diode bridge is wired

internally It also converts ac to dc but the dc output is varying

One advantage of a bridge rectifier over a conventional full-wave rectifier is

that with a given transformer the bridge rectifier produces a voltage output that is

nearly twice that of the conventional full-wave circuit

Filter

The output of the rectifier is a pulsating dc wave We need a constant dc

output To do this we need to filter out the oscillation from the pulsating dc wave

This is obtained with a diode capacitor combination

Voltage Regulator

A voltage regulator is used for voltage regulation in the circuit This provides

a protection to the circuits in the case of fluctuations It eliminates ripples by setting

dc output to fixed voltages

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 15

Fig 52 Block diagram of the power supply

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 16: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Load

The load can be anything which wants to switch ON by using power supply

513 CIRCUIT DIAGRAM EXPLANATION

Regulated power supplies are commonly used in engineering projects Power

supply is food of any circuit

+5V SUPPLY UNIT

+5V supply is obtained from the +5V supply unit for microcontroller and

digital ICs Initially 230 V AC supply is reduced to (0-9V) with the help of a step down

transformer having a capacity of 500mA

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 9VThis low voltage is rectified with the help

of bridge rectifier The ripples are minimized with the help of capacitor filter to get a

smooth DC supply The rating of the chosen capacitor filter is 1000microF

The regulated DC voltage is obtained by using a regulator IC 7805 In the

case of IC 7805 the unregulated DC voltage is applied to Pin 1 and the output is taken at

Pin 3 and Pin 2 is grounded Another capacitor filter of rating 10microF is connected at the

output of regulator IC to eliminate the voltage oscillations at the output due to the large

voltage oscillations at the input of the regulator

+12V SUPPLY UNIT

The plusmn12 V supply required by the relay is provided by the 12V supply circuit

arrangement Initially 230 V AC supply is reduced to (15V-0-15V) with the help of a

step down transformer having a capacity of 1A and the center tap of the transformer is

grounded This low voltage is rectified with the help off bridge rectifier

Since the input voltage to the regulator IC should be more than its output

voltage transformer secondary voltage is 15V-0-15VThe ripples are minimized with

the help of capacitor filter to get a smooth DC supply The rating of the chosen capacitor

filter is 1000microF The regulated DC output voltage is obtained by using regulator ICs

For regulated +12V DC supply IC 7812 is used and for regulated -12V DC supply IC

7912 is used

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 16

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 17: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

In the case of IC 7812 the unregulated DC voltage is applied to Pin 1 and

the output is taken at Pin 3 and Pin 2 is grounded The pair of capacitors of 10microF is

connected at the output as shown in figure to eliminate the voltage oscillations at the

output due to the large voltage oscillations at the input of the regulator

52 CONSTANT VOLTAGE CHARGER

521 CIRCUIT DIAGRAM

Fig 53 Circuit diagram of the battery charger

522 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 17

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 18: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Constant-voltage (often called constant-potential) chargers maintain nearly the same

voltage input to the battery throughout the charging process regardless of the batterys state

of charge Constant-voltage chargers provide a high initial current to the battery because of

the greater potential difference between the battery and charger

A constant-voltage charger may return as much as 70 of the previous discharge in

the first 30 minutes This proves useful in many battery applications involving multiple

discharge scenarios As the battery charges its voltage increases quickly This reduces the

potential that has been driving the current with a corresponding rapid decrease in charge

current as depicted in the illustration below As a result even though the battery reaches

partial charge quickly obtaining a full charge requires prolonged charging

Given this behavior constant-voltage chargers are frequently found in applications

that normally allow extended charging periods to attain full charge Constant-voltage

chargers should not be used where there is frequent cycling of the battery Repeated

discharges without returning the cell to its full charge will eventually decrease the battery

capacity and may damage individual cells

Fig 54An Illustration graph of the charging function of constant battery charger

Constant-voltage chargers are most often used in two very different modes as a fast

charger to restore a high percentage of charge in a short time or as a float charger to

minimize the effects of overcharge on batteries having infrequent discharges

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 18

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 19: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

53 RELAY DRIVER CIRCUIT

531 CIRCUIT DIAGRAM

532 CIRCUIT DIAGRAM EXPLANATION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 19

Fig 55 Relay driver circuit

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 20: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Input from the controller is connected to the relay card through connector J1 which

carries input signal for CH1 to CH4 to the base of integrated Darlington pair switch IC U1

pin number 1 to 4 and op is taken on the opposite pins ie pin 16 to 13

These outputs are connected to one end of the relay coil RL1 to RL4 ie pin no2 of

relay and other end of coil ie pin no5 is connected to +12V with A LED (J3 J5 J7 J9) in

series as shown in figureJ11 denoted as CHARGER IN carries the charging voltage +V

and GND (ground) where +V is commonly applied to pin 1 ie COM (common) contact of

relay and GND is shorted with pin1 of J4 J6 J8 and J10 Pin no 2 of J4 is connected to

NO(normally open)contact of RL1 ie pin no3in same way pin 2 of J6 is connected to pin

3 of RL2 pin 2 of J8 is connected to pin 3 of RL3 pin 2 of J10 is connected to pin 3 of

RL4 Pin no 8 of IC U1 is grounded and pin no9 which is COM is supplied with +12V J2

is used to connect power supply to relay card

533 WORKING

While taking Relay1 (RL1) into consideration we will discuss the working of relay

card Initially there is no signal or logic 0 on the pin1 of IC U1 hence the internal transistor

of the IC are in cut off region which causes an open circuit so there is no current flow

flowing through the relay coil hence the relay is inactive When a high signal or logic 1 is

applied to the two pin1 of IC U1 the internal transistor goes in to active region and

completes the path ie provide ground to the relay coil so the current flows through the

LED activating the relay

As the current flows through the relay coil it gets energized and switch over the

contacts ie common and normally open contact get connected and provide a path to flow

current from J11 ie charger into the load connected at J4 hence the cell phone charging

process starts The same above process is applies for all relays If LED is fused or

damaged the path will be open and relay will not be energized and if relay is damaged the

led will not be illuminated So the LED here is used as a FAULT indicator and a

CHARGING ON indicator

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 20

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 21: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

54 MICROCONTORLLER CIRCUIT

541 CIRCUIT DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 21 Fig 56 Microcontroller circuit diagram

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 22: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

542 CIRCUIT DIAGRAM EXPLANATION

CHANNEL SELECT SWITCH CH1 to CH4 are connected to port P00 to P03 with

the help of relimate connector denoted as SW1 to SW4 COIN IN signal is connected to

port P04 through J4 and START switch is connected to port P05 through SW5

Anodes of CHANNEL INDICATOR LED L1 to L4 are connected to port P10 to

P13 and cathodes are connected to ground through 470Ω series resistor R2 to R5

Output for relay card is taken on port P14 to P17

Components C1 R1 and push button S1 forms reset circuit which provides a power

on reset for the micro controller and even provide manual reset Crystal XL1 is a

110592MHz crystal connected to pin 18 and 19 of microcontroller capacitor C2 and C3 are

22pf capacitor used as loading capacitor for crystal

Port 0 and Port 1 is pulled up using a 47KΩ SIP (Single Inline Package) RN1 and

RN2 resistance network

IC U3 (4N33) is an OPTO-COUPLER which is used to provide isolation between

the proximity switch and microcontroller and convert its output readable to microcontroller

IC U2 ie MAX232 and capacitor C6 to C9 forms a circuit used to establish

communication between PC and a microcontroller through connector J3

Led L9 and L10 with a series resistor R6 and R7 indicates the ongoing

communication process

Where C4 and C5 are used as filter capacitor terminal block J1is used to facilitate

power supply connection

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 22

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

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Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 23: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

543 PORT ASSIGNMENTS FOR 89V51RD2FN

P00 = switch1 for channel 1

P01 = switch2 for channel 2

P02 = switch3 for channel 3

P03 = switch4 for channel 4

P04 = switch5 for coin input sensor (proximity switch)

P05 = switch6 for start charging

P10 = channel 1 red LED1 (ready system)

P11 = channel 2 red LED2 (ready system2)

P12 = channel 3 red LED3 (ready system3)

P13 = channel 4 red LED4 (ready system4)

P14 = channel 1 relay (start system1)

P15 = channel 2 relay (start system2)

P16 = channel 3 relay (start system3)

P17 = channel 4 relay (start system4)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 23

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

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Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 24: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 6

LIST OF THE

COMPONENTS

List of the components

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 24

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 25: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

61 LIST OF THE COMPONETS

RESISTORS

CAPACITORS

LIGHT EMITING DIODES (LEDS)- Green Red

RELAYrsquoS-

TRANSFORMERS

RECTIFIER BRIDGES (W 10)

OSCILLATOR

SWITCHES- Push switches

DARLINGTON PAIR IC (ULN2003a)

SERIES VOLTAGE REGULATER IC (78XX)-7805 amp 7812

SERIAL COMMUNICATION DRIVER IC (MAX 232)

OPTOCOUPLER IC (4N33)

MICROCONTROLLER IC (89V51 RD2)

RELIMATE CONNECTOR- 2 pin amp 4 pin

RS-232 PORT CONNECTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 25

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 26: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 7

INTRODUCTION

OF COMPONENTS

Working of components

Features or Uses of components

Testing of components

71 RESISTOR

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 26

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 27: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

711 WORKING

Resistors limit current Resistors are considered to be the most used and the most

important component of all the electronic circuits Resistors resist the flow of electrical

current The higher the value of resistance (measured in ohms)

the lower the current will be

712 TESTING

Read the indicated color code value then select the OHM-scale within but not way

below the indicated value A resistor is good if its resistance is close to the indicated

Tolerance should be considered with the ohmmeter reading While no resistance reading at

all on the ohmmeter scale settings the resistor is open A zero resistance reading on all

ohmmeter scale settings resistor is shorted

713 SPECIFICATIONS

To completely specify a resistors characteristics requires knowledge of the following

parameters-

bull Value

bull Tolerance

bull Temperature Coefficient

bull Power Rating

The specification of a resistor may be marked on its surface using either of two

systems of coding The first of these uses colored bands known as the rsquocolour codersquo and

the second more recent system uses a combination of alpha-numeric characters

7 2 CAPACITOR

721 WORKING

When DC voltage is applied to the capacitor an electric charge is stored on each

electrode While the capacitor is charging up current flows The current will stop flowing

when the capacitor has fully charged Capacitors find use

in circuits for a variety of purposes They are used in

time delay generation RC circuits In power supplies for filtering and power supply

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 27

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 28: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

decoupling as blocking capacitors for power factor correction and motor starting in LC

tank circuits and so on

722 TESTING

To test a capacitor set the multi-tester to Rx 10 or Rx1K scale Connect the tester

negative probe to the capacitor positive terminal the positive probe to the negative terminal

A good indication for electrolytic capacitor shows the meter needle deflecting towards zero

and moves back again to infinite resistance position A defective indication for an

electrolytic capacitor shows that the meter will rest on zero and remain stationary at a point

which is an indication that the capacitor is shorted

73 LIGHT EMITING DIODE (LED)

731 WORKING

LEDs are special diodes that emit light when

connected in a circuit They are frequently used as pilot lights in electronic appliances to

indicate whether the circuit is closed or not A clear (or often colored) epoxy case enclosed

the heart of an LED the semi-conductor chip

In our project Green LED are used here for mainly two purpose

a Charging ON indication (when ON)

b Channel fault indication (always OFF)

732 TESTING

The good and working LED will then light up or glow a busted LED will not LEDs

must have a resistor in series to limit the current to a safe value for quick testing purposes a

1k resistor is suitable for most LEDs if your supply voltage is 12V or less LED cannot be

directly connected to a battery or power supply It will be destroyed the LED

733 FEATURES

Single color

High bright output

Low power consumption

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 28

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 29: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

High reliability and long life

734 Descriptions

Dice material GaInN

Emitting Color Super Bright White

Device Outlineφ5mm Round Type

Lens Type Water Clear

74 RELAY

741 WORKING

A relay is an electrically operated switch Current

flowing through the coil of the relay creates a magnetic field

which attracts a lever and changes the switch contacts The coil

current can be on or off so relays have two switch positions and

most have double throw (changeover) switch contacts

Relays are like remote control switches and are used in

many applications because of their relative simplicity long life

and proven high reliability

742 USES

The main operation of a relay comes in places where only a low-power signal can be

used to control a circuit

It is also used in places where only one signal can be used to control a lot of circuits

The application of relays started during the invention of telephones They played an

important role in switching calls in telephone exchanges They were also used in

long distance telegraphy They were used to switch the signal coming from one

source to another destination

743 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 29

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

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ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 30: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

A relay will usually have a coil pole terminal and a set of

contacts The set of contacts that are open when the relay is not

energized are called normally open (NO) contacts and the set of

contacts that are closed when the relay is not energized are called

normally closed (NC) contacts The following steps can be used to perform the testing of

the relay using a multimeter

Keep the multimeter in the continuity check mode

Check for continuity between the NC contacts and pole

Check for discontinuity between NO contacts and the pole

Now energies the relay using the rated voltage For example use a 9V battery for

energizing a 9V relay The relay will engage with clicking sound

Now check for continuity between NO contacts and pole

Also check for discontinuity between NC contacts and pole

As a final test measure the resistance of the relay coil using a multimeter and check

whether it is matching to the value stated by the manufacturer

If all the above tests are positive we can conclude that the relay is healthy

75 TRANSFORMER

751 WORKING

A transformer is a device that transfers electrical energy

from one circuit to another through inductively coupled

electrical conductors A changing current in the first circuit (the

primary) creates a changing magnetic field

This changing magnetic field induces a changing voltage in the second circuit (the

secondary) This effect is called mutual induction

If a load is connected to the secondary circuit electric charge will flow in the

secondary winding of the transformer and transfer energy from the primary circuit to the

load In an ideal transformer the induced voltage in the secondary winding (VS) is a fraction

of the primary voltage (VP) and is given by the ratio of the number of secondary turns to the

number of primary turns

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 30

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 31: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

By appropriate selection of the numbers of turns a transformer thus allows an

alternating voltage to be stepped up mdash by making NS more than NP mdash or stepped down by

making it less

752 TESTING

1 The ohm meter is the deciding factor Putting the ohm meter on the lowest

scale and then adjusting the knob to verify its reading is an easy step to the

reading of the ohm

2 To check the resistance of the coil unplug or unsolder the leads of the

transformer from its circuit and measure the resistance of each coil

3 The next step is to test each coil for shorts to other coils

76 RECTIFIER BRIDGE (W 10)

761 WORKING

A diode bridge rectifier is a device for converting AC or

alternating current electricity into DC or direct current AC

electricity goes from positive to negative constantly whereas DC

always flows in the same direction

AC electricity is more efficient to transmit and easier to

convert into different voltages However most appliances need DC current to run A diode

bridge rectifier is the most common type of power supply used to provide this current In

our project W10 is a bridge rectifier which provides on single semiconductor chip

77 OSCILLATOR

771 Working

An oscillator puts out an endless series of pulses The output

constantly goes from 0 volts to Vcc and back to 0 volts again Almost

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 31

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 32: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

all digital circuits have some type of oscillator This stream of output pulses is often

called a clock One of the most important features of any oscillator is its frequency stability

or in other words its ability to provide a constant frequency output under varying load

conditions Some of the factors that affect the frequency stability of an oscillator include

temperature variations in the load and changes in the DC power supply Frequency stability

of the output signal can be improved by the proper selection of the components used for the

resonant feedback circuit including the amplifier but there is a limit to the stability that can

be obtained from normal LC and RC tank circuits

In our project instead of 12MHz crystal 110592MHz is used because it can be

divided to give you exact clock rates for most of the common baud rates for the UART

especially for the higher speeds (9600 19200) These crystals are readily available and

commonly used

78 SWITCH

781 WORKING

The most familiar form of switch is a manually operated

electromechanical device with one or more sets of electrical contacts

Each set of contacts can be in one of two states either closed meaning

the contacts are touching and electricity can flow between them or

open meaning the contacts are separated and the switch is non

conducting The mechanism actuating the transition between these two

states (open or closed) can be either a toggle (flip switch for continuous on or off) or

momentary (push-for on or push-for off) type

782 USES

In electronics a switch is an electrical component that can break an electrical

circuit interrupting the current or diverting it from one conductor to another

783 TESTING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 32

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 33: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the switch is ON it looks and acts like a wire When the switch is OFF there is

no connection Switch can tested by using multimeter in continuity range

79 DARLINGTON PAIR IC (ULN2003a)

791 WORKING

The Darlington transistor (often called a Darlington pair) is a

compound structure consisting of two bipolar transistors (either

integrated or separated devices) connected in such a way that the

current amplified by the first transistor is amplified further by the

second one This configuration gives a much higher current gain than

each transistor taken separately and in the case of integrated devices

can take less space than two individual transistors because they can

use a shared collector

Integrated Darlington pairs come packaged singly in

transistor-like packages or as an array of devices (usually eight) in an integrated circuit

The Darlington transistor array used is ULN2003 Applications include relay

drivers hammer drivers lamp drivers display drivers (LED and gas discharge) line

drivers and logic buffers Each input of this device has a zener diode and resistor in series

to control the input current to a safe limit The ULN2003A has a 27-k Ω series base resistor

for each Darlington pair for operation directly with TTL or 5-V CMOS devices

792 FEATURES

The ULN2003 is16 pins DIP monolithic high-voltage high-current Darlington

transistor array It consists of seven NPN Darlington pairs that feature high-voltage outputs

with common-cathode clamp diodes for switching inductive loads The collector-current

rating of a single Darlington pair is 500 mA The Darlington pairs may be paralleled for

higher current capability

710 SERIES VOLTAGE REGULATER IC (78XX)

7101 WORKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 33

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 34: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Voltage Regulator (regulator) usually having three legs converts varying input

voltage and produces a constant regulated output voltage They are available in a variety of

outputs

The most common part numbers start with the numbers 78 or 79 and finish with two

digits indicating the output voltage The number 78 represents positive voltage and 79

negative one The 78XX series of voltage regulators are designed for positive input

The LM78XX series typically has the ability to drive current up to 1A For

application requirements up to 150mA 78LXX can be used As mentioned above the

component has three legs Input leg which can hold up to 36VDC Common leg (GND) and

an output leg with the regulators voltage

As a general rule the input voltage should be limited to 2 to 3 volts above the output

voltage The LM78XX series can handle up to 36 volts input be advised that the power

difference between the input and output appears as heat If the input voltage is unnecessarily

high the regulator will overheat Unless sufficient heat dissipation is provided through heat

sinking the regulator will shut down

711 SERIAL COMMUNICATION DRIVER IC (MAX 232)

7111 WORKING

The MAX-232 It includes a Charge Pump which generates

+10V and -10V from a single 5v supply

This IC also includes two receivers and two transmitters in

the same package This is handy in many cases when we only want to

use the Transmit and Receive data Lines We dont need to use two chips one for the

receive line and one for the transmit There are also many variations of these devices The

large value of capacitors are not only bulky but also expensive Therefore other devices are

available which use smaller capacitors and even some with inbuilt capacitors However the

MAX-232 is the most common and thus we will use this RS-232 Level Converter

Dual Charge-Pump Voltage Converter

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 34

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 35: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The first converter uses capacitor C1 to double the +5V input to +10V on C3 at the

V+ output The second converter uses capacitor C2 to invert +10V to -10V on C4 at the V-

output

712 OPTOCOUPLER IC (4N33)

7121 WORKING

In electronics an opto-isolator (or optical isolator optocoupler photocoupler or

photoMOS) is a device that uses a short optical transmission path to transfer a signal

between elements of a circuit typically a transmitter and a receiver while keeping them

electrically isolated mdash since the signal goes from an electrical signal to an optical signal

back to an electrical signal electrical contact along the path is broken

Optocouplers typically come in a small 6-pin or 8-pin IC package but are

essentially a combination of two distinct devices an optical transmitter typically a gallium

arsenide LED (light-emitting diode) and an optical receiver such as a phototransistor or

light-triggered diac The two are separated by a transparent barrier which blocks any

electrical current flow between the two but does allow the passage of light

The 4N33 are optically coupled isolators with a gallium arsenide infrared LED and a

silicon photo Darlington sensor Switching can be achieved while maintaining a high degree

of isolation between driving and load circuits These Optocouplers can be used to replace

reed and mercury relays with advantages of long life high speed switching and elimination

of magnetic field

713 MICROCONTROLLER IC (89V51 RD 2 )

713 WORKING

The P89V51RD2 is an 80C51 microcontroller with 64

kB Flash and 1024 bytes of data RAM

A key feature of the P89V51RD2 is its X2 mode option

The design engineer can choose to run the application with the conventional 80C51 clock

rate (12 clocks per machine cycle) or select the X2 mode (6 clocks per machine cycle) to

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 35

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

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PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 36: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

achieve twice the throughput at the same clock frequency Another way to benefit from this

feature is to keep the same performance by reducing the clock frequency by half thus

dramatically reducing the EMI

The Flash program memory supports both parallel programming and in serial In-

System Programming (ISP) Parallel programming mode offers gang-programming at high

speed reducing programming costs and time to market ISP allows a device to be

reprogrammed in the end product under software control The capability to fieldupdate the

application firmware makes a wide range of applications possible The P89V51RD2 is also

In-Application Programmable (IAP) allowing the Flash program memory to be

reconfigured even while the application is running

714 RELIMATE CONNECTOR

7141 WORKING

These are wire to board type connectors used to facilitate

proper and firm electrical connection between the relay card and

microcontroller card

The connector has following specifications

No of Ways 2-20

Voltage Rating 250V AC DC

Current Rating 3A AC DC

Contact Resistance 20mW max

Insulation Resistance 1000MW min

Dielectric Withstanding 1000V ACminute

Crimp Terminal Wire Size 22-28 AWG (American wire gauge)

The connector used for relay card is 2 PIN and 4 PIN connector Advantage of the

connector is it provides a fast and easy connection and disconnection it also avoids polarity

conflicts

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 36

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 37: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

715 RS-232 PORT CONNECTOR

7151 WORKING

Almost all digital devices which we use require either TTL

or CMOS logic levels Therefore the first step to connecting a

device to the RS-232 port is to transform the RS-232 levels back

into 0 and 5 Volts This is done by RS-232 Level Converters

Two common RS-232 Level Converters are the 1488 RS-232 Driver and the 1489 RS-232

Receiver Each package contains 4 inverters of the one type either Drivers or Receivers

The driver requires two supply rails +75 to +15v and -75 to -15v This may pose a

problem in many instances where only a single supply of +5V is present

CHAPTER 8

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 37

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 38: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

IMPLIMENTATION

OF THE PCB

Components layout designing

Developing or Etching the PCB

Other operations like Drilling Cutting Tinning

81 IMPLIMENTATION OF THE PCB

A proper PCB ensure that various circuit components are interconnected as per the

circuit diagram once they have been placed on the PCB in their proper positions and

subsequently soldered A Printed Circuit Board (PCB) can be defined as an insulating

base material to which is permanently attached a flat metallic network of conducting path

whose dimension depends upon the current that can be handled by them Four PCBrsquoS used

for this project is single one

The basic material used may be resin coated paper fiber glass ceramic and the flat

board configuration however is most widely used and it may be of the nature of the single

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 38

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 39: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ldquoMother Boardrdquo into which smaller board are plugged by specially designed connectors

which ensures adequate and permanent low resistance coupling

811 BOARD DESIGN

PCB designed is the most important and requires great care during work In this case

great care must be taken while tracing the circuit or layout on the board Because once PCB

is designed it is virtually impossible to alter it While designing a circuit designer should

take care to avoid crossing of conducting path (tracks) as possible Crossover are

unavoidable then only of the jumper can be used A circuit board carrying on both sides can

also help to solve this problem when circuit is complicated

812 THE MASTER DIAGRAM

The next stage lies in proportion to designing ie to prepare lsquoMaster Diagram ldquo

which is commonly made twice as the finished circuit since this makes the working on that

much easier especially when circuit is complicated photography eventually reduces the

size of diagram to that of the circuit before proceeding we must know some rules regarding

the designing -

a The space between the conductors must be strictly controlled to avoid the possibility

of electrical discharges or unwanted capacitance The amount by which the mater

diagram is to reduce in size is thus a critical deign feature

b The conductor must be wider in those part of the circuits that are going to handle

large current must be handle without undue temperature of conductors

c The minimum width of copper should not generally be less than about 15mmThis

is related to mechanical strength rather than electrical properties and it also ensure

that strips remains securely bounded to the base material

d The points where the component holes for component lead wire occurs must be sited

to suit the dimensions of the component and dimensions between lead-out wire so

that the components can be situated correctly on finished board The conductor is

also main large at the point of holes

813 PCB MAKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 39

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 40: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When the mater diagram probable twice the size of real PCB has been evolved the

test major step consists of etching or dissolving the unwanted metal from copper claded

board to create a circuit as depicted by master diagram It must be stressed that very

accurate checking master is essential at this stage Then the master point is mounted on a

special frame on easy facing of a larger camera and with the aid of the very powerful

illumination a master diagram is clearly photographed on a glass sensitive plate This is

developed to give photographic negative Next is called ldquostep and repeat camerardquo It is

brought into operation This comprises the camera body mounted so that sideways after

each exposure In this way number of copies of the original master diagram is set out

exactly to cover standard sheet of copper clad laminate laboratory method of making PCB

In case of simple and need of number of less PCB economic and advisable to use the

following lab method of PCB making

Planning The Circuit

It is not a particular difficult There are several important factors that need not be

taken into account if the finished device is to work properly we must consider gain factor

and ensure that the input and output parts are sufficiently well isolated to avoid the

possibility We must also ensure that conductors and components carrying high frequency

current are well separated from the part of the circuit We are also to make sure that all

components need to return to earth are properly connected and that possibility of common

impedance arising earth returned

Circuit is totally eliminated by making all earth as substantial possible consistent

with nature of design Other factors that have to successfully studied include availability of

adequate return points on board and itrsquos mounting from accessibility of switch connection

made for mechanical fixing ventilation effect of vibration

Cleaning The Board

The copper side of the board must be thoroughly cleaned before circuit plan is

transferred to it This is important because even slightest trace of graze (from figure of

instance) will impure the etching process and when the circuit plan has been neatly

transferred to copper in this manner the board is held under running tap and the allowed to

dry before resist is applied

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 40

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 41: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Transforming the Plan

Now once cleaning is done plan has to transfer on copper surface of PCB material

A convenient way to do this is simply put the carbon paper between a copper surface of the

board and working plan and carefully trace the lines of original plan with a ball pen

Resist

Resist is nothing more than a substrate that is unaffected by presence etching

chemicals It is usually colored so that it can be easily seen the copper surface when plan is

clearly worked on clean copper that are to be left in fact as the copper conductor must be

covered when resists the leaguer type of paints possess good resist properties but

disadvantage of relatively long time taken for drying It is essential to resist through

hardening before etching is started Nail polished are better as they quickly and are less

difficult to remove

To overcome this drying effect and to achieve the sharp edge of the trace on the

PCB Now-a-days etching taps along with IC pads are commonly used To this chances of

short circulating due to paints are completely the avoid etching tapes and pads are available

in different sizes

Correcting Error

When a result has been thoroughly hardened any errors that have been made can

usually be corrected by gently scratching away with knife To ensure clear out lines round

edges of copper conductors on board the resist must be applied with steady band

Etching

Next comes etching of unwanted copper amp whether a small single is all that is

required as quantity of board to be produce certain precautions must be taken before

operation is commenced the most used etch amp I ferrite chloride to this is added small

quantity of HCL to accelerate But not critical as lab construction concerned A good

etchant can be produced by mixing 10grams of ferric chloride amp 25 grams of HCL with 15

grams of water

Agitation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 41

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 42: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Small plastic bath is ideal for storing the etchant process Depth of liquid for storing

the etchant process The depth of liquid must be sufficient to completely cover laminate the

laminated board carrying the resist patterns circuit is then cropped into etchant bath amp the

gentle agitation takes 5 to 20 minutes to complete depending on the strength of the enchant

temperature and thickness of copper foil

Finishing Off

When all unwanted copper is dissolved from areas between conductor board should

be taken from an etchant amp washed in water The resist must be removed using proper

solvent After this the copper surface must be polished with any kind of cleaner It should be

seen that there is no slight incomplete etching between the conducting parts of the PCB The

PCBrsquos are coated coating material for protection in lab coating material itself it a soldier

This process is called Tinning This process of coating involve track with soldier

Advantage of tinning the effect of environment of conductors then PCB is drilled

ie holes for filling amp mounting the component on PCB are drilled with suitable drill bit

Assembling On PCB

After the holes are drilled the component have to be assembled on PCB before

assembling the components it is necessary to clean soldering iron in order to get easy amp

accurate soldering Removing impurity particles that are gathered on iron bit due to

repetitive use cleans soldering iron

CHAPTER 9

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 42

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 43: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

SOLDERING

TECHNIQUE

Technique for good soldering

91 SOLDERING TECHNIQUE

For soldering of any joints first the terminal to be soldered are cleaned to remove

oxide film or dirt on it If required flux is applied on the points to be soldered

Now the joint to be soldered is heated with the help of soldering iron Heat

applied should be such that when solder wire is touched to joint it must melt

quickly

The joint and the soldering iron is held such that molten solder should flow

smoothly over the joint

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 43

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 44: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

When joint is completely covered with molten solder the soldering iron is re-

moved

The joint is allowed to cool without any movement

The bright shining solder indicates good soldering

In case of dry solder joint a air gap remains in between the solder material and

the joint It means that soldering is improper This is removed and again solder-

ing is done

Thus this way all the components are soldered on P C B

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 44

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 45: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 10

PCB LAYOUTS

Schematic diagram

Bottom and top layout

101 POWER SUPPLY CARD

1011 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 45

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 46: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1012 LEGEND MARKING

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 46

Fig1011 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 47: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1013TOP LAYER

1014 BOTTOM LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 47

Fig1013 Top layer of power supply

card

Fig1014 Schematic diagram of power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 48: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

102 BATTERY CHARGER CARD

1021 SCHEMATIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 48

Fig1021 Schematic diagram of battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 49: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

103 RELAY CARD

1031 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 49

Fig1031 Schematic diagram of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 50: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1032 RELAY CARD LEGEND MARKING

1033 TOP LAYER

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 50

Fig1032 Legend marking of Relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 51: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1034 BOTTOM LAYER

104 MICROCONTROLER CARD

1041 SCHIMETIC DIAGRAM

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 51

Fig1034 Bottom layer of Relay card

Fig1041 Schematic diagram of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 52: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1042 ALL LAYERS

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 52

Fig1042 All layer of microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 53: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 11

INTRODUCTION

OF SOFTWARE

Keil (microVision 2)

Eagle (Easily Applicable Graphical Layout Editor)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 53

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 54: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

111 Keil (microVision 2)

1111 Introduction to C51 Cross Compiler

The Keil C51 Cross Compiler is an ANSI C Compiler that is written specifically to

generate fast compact code for the 8051 microcontroller family The C51 Compiler

generates object code that matches the efficiency and speed of assembly programming

Using a high-level language like C has many advantages over assembly language

programming

Knowledge of the processor instruction set is not required Rudimentary knowledge of

the memory structure of the 8051 CPU is desirable (but not necessary)

Details like register allocation and addressing of the various memory types and data

types is managed by the compiler

Programs get a formal structure (which is imposed by the C programming language) and

can be divided into separate functions This contributes to source code reusability as

well as better overall application structure

The ability to combine variable selection with specific operations improves program

readability

Keywords and operational functions that more nearly resemble the human thought

process may be used

Programming and program test time is drastically reduced

The C run-time library contains many standard routines such as formatted output

numeric conversions and floating-point arithmetic

Existing program parts can be more easily included into new programs because of

modular program construction techniques

The language C is a very portable language (based on the ANSI standard) that enjoys

wide popular support and is easily obtained for most systems Existing program

investments can be quickly adapted to other processors as needed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 54

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 55: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1112 Software Development Cycle in Keil

When we use the Keil Software tools the

project development cycle is roughly the same as

it is for any other software development project

1 Create a project select the target chip from the

device database and configure the tool settings

2 Create source files in C or assembly

3 Build your application with the project

manager

4 Correct errors in source files

5 Test the linked application A block diagram of

the complete 8051 tool set may best illustrate the

development cycle

112 Eagle (Easily Applicable Graphical Layout Editor)

The EAGLE is an editor which is easy-to-use yet powerful tool for designing

printed circuit boards (PCBs) It is a complete platform for the development of any type of

complicated amp sophisticated multilayered PCBs This software consist of the following tool

1121 Schematic Editor

In this one can develop amp design circuits for the required PCB

1122 Layout Editor

In this one can develop amp design actual PCB structure required This is done automatically by the software using the circuit in the schematic editor itself

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 55

Fig 111 Software development in KEIL

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 56: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1123 Library Editor

This is very useful in case of customized component design that does not occur in the predefined library according to our need

1124 Auto Router

This is an artificial intelligence based tool or subroutine that can do auto routing of

the PCB tracks designed

1125 Cam Processor

This is used to finally print the various layers of the designed PCB viz Top Layer

Bottom Layer Component Layer Masking Layer etc

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 56

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 57: automatic coin operated mobile batery charger

TIMER INITIALISATIONTR0=0 TF0=0 TL0=0XFD TH0=0X4B TR0=1

Start

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 12

INTRODUCTION

OF

PROGRAMMING

Flowchart of programming

Program code

121 Flowchart

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 57

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 58: automatic coin operated mobile batery charger

2

flag9==1

flag9=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 58

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 59: automatic coin operated mobile batery charger

flag11==1

flag11=1 flag11=0 flag4=0

REady_LED4=0

Sw2_op (P01) ==0

My delay (10)

3 3

flag2=1 disp2=1 k2=0

3

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 59

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 60: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 60

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 61: automatic coin operated mobile batery charger

4

flag11==1

flag11=0 flag4=0 REady_LED4=0

flag11=1

My delay (10)

flag3=1 disp3=1 k3=0

k1==0||k2==0||k4==0

Sw3_op (P02) ==0

5

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 61

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 62: automatic coin operated mobile batery charger

flag5==1

5

flag11==1

flag7=1

flag7==1

flag7=0 flag2=0 REady_LED2=0

6

flag5=1 flag5=0 flag1=0 REady_LED1=0 REady_LED1=0

flag11=0 flag4=0 REady_LED4=0

flag11=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 62

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 63: automatic coin operated mobile batery charger

6

My delay (10)

flag4=1 disp4=1 k4=0

k1==0||k2==0||k3==0 flag5==1

7

Sw4_op (P03) ==0

flag5=1 flag5=0 flag1=0 REady_LED1=0

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 63

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 64: automatic coin operated mobile batery charger

7

flag7==1

flag9==1

flag7=1

flag7=0 flag2=0 REady_LED2=0

flag9=0 flag3=0 REady_LED3=0

flag9=1

Sw5_op A(P04) ==0

My delay (10)

8

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 64

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 65: automatic coin operated mobile batery charger

9

flag2==1

flag3==1

8

flag1==1

flag4==1 flag5=1 disp5=1

flag9=1 disp5=1

flag7=1 disp5=1

flag11=1 disp5=1

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 65

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 66: automatic coin operated mobile batery charger

Sw6_op (P05) ==0

My delay (10)

flag2==1 ampamp flag7==1

flag3==1 ampamp flag9==1 9

flag1==1 ampamp flag5==1 flag6=1 disp6=1

flag8=1 disp6=1

10

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 66

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 67: automatic coin operated mobile batery charger

10

flag4==1 ampamp flag11==1

flag10=1 disp6=1

flag12=1 disp6=1

flag8==1

flag10==1

11

flag6==1

i++

l++

j++

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 67

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 68: automatic coin operated mobile batery charger

flag12==1

M++

11

Stop

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 68

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 69: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

122 Program

includeltstdiohgtincludeltstringhgtincludeIDA51HincludeREG52H

define buzzerP2_0 buzzer indication

setting of ip switch for following operation sbit sw1_op=P0^0 input SWITCH1 for sytem1sbit sw2_op=P0^1 input SWITCH2 for sytem2sbit sw3_op=P0^2 input switch3 for sytem3sbit sw4_op=P0^3 input switch4 for sytem4

sbit sw5_op=P0^4 input switch5 for coin

sbit sw6_op=P0^5 input switch for startsbit sw7_op=P3^7 input switch for exit

output Led for indication

sbit REady_LED1=P1^0 LED1 indication (ready system1)sbit REady_LED2=P1^1 LED2 indication(ready system2)sbit REady_LED3=P1^2 LED3 indication(ready system3)sbit REady_LED4=P1^3 LED4 indication(ready system4)

sbit START_LED1=P1^4 LED1 indication(start system1 )sbit START_LED2=P1^5 LED2 indication(start system2 )sbit START_LED3=P1^6 LED3 indication(start system3 )sbit START_LED4=P1^7 LED4 indication(start system4 )

function prototype declaration

void my_delay(unsigned int value) DELAY FUCTION

void init_timer() timer 0 initialization function

variable declaration

bit flag1flag2flag3flag4flag5flag6flag7flag8flag9flag10flag11flag12bit disp1=0disp2=0disp3=0disp4=0disp5=0disp6=0k1=1k2=2k3=1k4=1unsigned long int i=0j=0l=0m=0ii=0ll=0jj=0mm=0 k=390(1 minute) k=50

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 69

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 70: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

start of main programme

void main()

init_timer() call it timer initialization function

REady_LED1=0REady_LED2=0REady_LED3=0REady_LED4=0 clear Ready indication led

START_LED1=0START_LED2=0START_LED3=0START_LED4=0 clear start indication led

start of while loop

while(1) while loop with condition always equal to 1 to repeat loop infinite times unless and until we shut down the system

condition for switch1

if(flag1==1) check swich1 pressed if(disp1==1 )

REady_LED1=1 turn on Ready indication of led 1 disp1=0

if(flag5==1) check coin is pressed if(flag6==1) START is pressed and start conversion

if(iltk) loop will repeat for desired time of charging

if(igt=1000)

buzzer=1 turn on buzzer if (ii==20)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 70

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 71: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED1=1 turn on ready indication of led1

else if(ii==40)

REady_LED1=0ii=0

elseREady_LED1=0

START_LED1=1

else

START_LED1=0

k1=1 buzzer=0

REady_LED1=0 flag1=0

flag5=0flag6=0

condition for switch2

if(flag2==1) check swich2 pressed if(disp2==1)

REady_LED2=1 turn on ready 2 led indication

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 71

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 72: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp2=0

if(flag7==1) check coin is pressed if(flag8==1) START is pressed

if(jltk)

if(jgt1000) buzzer=1 if(jj==20)

REady_LED2=1else if(jj==40)REady_LED2=0jj=0

elseREady_LED2=0

START_LED2=1

else START_LED2=0

REady_LED2=0 k2=1 buzzer=0

flag2=0flag7=0flag8=0

j=0jj=0

condition for switch 3

if(flag3==1) check swich3 pressed

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 72

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 73: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if(disp3==1 )

REady_LED3=1 disp3=0

if(flag9==1) check coin is pressed if(flag10==1) START is pressed

if(lltk)

if(lgt1000) buzzer=1 if(ll==20)

REady_LED3=1else if(ll==40)REady_LED3=0ll=0

elseREady_LED3=0

START_LED3=1

else START_LED3=0

LED2=0 k3=1 buzzer=0

REady_LED3=0 flag3=0

flag9=0flag10=0

l=0ll=0

condition for switch 4

if(flag4==1) check swich4 pressed if(disp4==1 )

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 73

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 74: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

REady_LED4=1 disp4=0

if(flag11==1) check coin is pressed

if(flag12==1) START is pressed

if(mltk)

if(mgt1000)

buzzer=1 if(mm==20)

REady_LED4=1else if(mm==40)REady_LED4=0mm=0

elseREady_LED4=0

START_LED4=1

else START_LED4=0

buzzer=0 k4=1

REady_LED4=0 flag4=0

flag11=0flag12=0

m=0mm=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 74

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 75: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

while(1)

end of main programme

timer delayvoid init_timer() TMOD=0x01 timer 0 in mode 1

TL0=0xfd timer lower valueTH0=0x4b timer higher valueIE|=0x82 interrupt control bitTR0=1 start timer bit

whenever specific time the interrupt will generate control will go in following function

void timer0_isr(void)interrupt 1 using 2 timer 0 interrupt TR0=0 reset timer TF0=0 reset over flow flag TL0=0xfd load value of TL0 TH0=0x4b LOAD VALUE OF TH0 TR0=1 SET TIMER BIT OR TURN ON TIMER IF SWITCH 1 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw1_op==0 ) ready switch flag for system1

my_delay(10) CALL DELAY FUNCTION

flag1=1 SET RESPECTIVE FLAG FOR NEXT OPERATION disp1=1 k1=0

if(k2==0||k3==0||k4==0) IF SWITCH2OR SWITCH3 OR SWITCH 4 IS PRESSED THEN IT WILL GO INTO FOLLOWING LOOOP

if(flag7==1) SET THE FLAG

flag7=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 75

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 76: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag7=0flag2=0REady_LED2=0 CLEAR READY 2 LED if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 CLEAR READY 3 LED if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0 CLEAR READY 4 LED

IF SWITCH 2 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw2_op==0 ) fready switch flag for system2

my_delay (10)

flag2=1 disp2=1 k2=0 if(k1==0||k3==0||k4==0)

if(flag5==1)

flag5=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 76

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 77: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

elseflag5=0 flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 3 IS PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw3_op==0 ) ready switch flag for system3 my_delay(10)

flag3=1 disp3=1 k3=0 if(k2==0||k1==0||k4==0)

if(flag7==1)

flag7=1

else

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 77

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 78: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag7=0flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag11==1)

flag11=1

elseflag11=0flag4=0REady_LED4=0

IF SWITCH 4 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw4_op==0 ) ready switch flag for system4 my_delay(10) flag4=1 disp4=1 k4=0 if(k2==0||k1==0||k3==0)

if(flag7==1)

flag7=1

elseflag7=0

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 78

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 79: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

flag2=0REady_LED2=0 if(flag5==1)

flag5=1

elseflag5=0flag1=0REady_LED1=0 if(flag9==1)

flag9=1

elseflag9=0flag3=0REady_LED3=0

IF SWITCH 5 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if (sw5_op==0 ) coin check my_delay (10) if (flag1==1) flag5=1 disp5=1

if(flag2==1 ) flag7=1 disp5=1 if(flag3==1 ) flag9=1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 79

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 80: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

disp5=1 if(flag4==1 ) flag11=1 disp5=1

IF SWITCH 6 IES PRESSEDE THEN IT WILL GO N TO FOLLOWING LOOP

if(sw6_op==0 ) start signal my_delay (10) if((flag1==1 ampamp flag5==1)) flag6=1 disp6=1 if((flag2==1 ampamp flag7==1)) flag8=1 disp6=1

if((flag3==1 ampamp flag9==1)) flag10=1 disp6=1 if((flag4==1 ampamp flag11==1)) flag12=1 disp6=1

if(flag6==1)

i++ if (igt1000) ii++

if (flag8==1)

j++ if(jgt1000) jj++

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 80

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 81: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

if (flag10==1)

l++ if (lgt1000) ll++

if (flag12==1)

m++ if (mgt1000) mm++

DELAY FUNCTIONvoid my_delay(unsigned int value) unsigned int x y for(x=0xlt1000x++) for(y=0yltvalue y++)

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 81

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 82: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 13

TROUBLE SHOOT

Troubleshoot

131 TROUBLE SHOOT

A newly assembled circuit does not work may be due to -

Faulty components

Improper soldering

Wrong connections

Also any stop in working after some period may be due to -

Component failure

Supply failure

Damaging of PCB

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 82

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 83: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fault finding is very essential if you want the circuit to operate properly

If a newly assembled circuit is not working properly check all the components and

circuit connections according to the diagram The circuit may not be working due to wrong

polarity of capacitor diode and wrong supply terminal connection Most of the times the

circuit does not work due to bad soldering Therefore proper procedure is followed to have

proper soldering

If faults are not observed during physical observations one should proceed for Hot

test ie Voltage measurement at different points for example at Input terminal etc

Resistance measurement is also done which is known as Dry test

During this project work some green LEDs was not glow then we checked it

continuity and replace it

Also relay was not properly worked therefore we replaced it Some ICs was get

heated after starting the project It happens because of some soldering points are shorted

during soldering PCB We solved that problem

CHAPTER 14

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 83

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 84: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

ADVANTAGES OF

THE PROJECT

Advantages

141 ADVANTAGES OF THE PROJECT

Simple and hand efficient Microcontroller based system

Fast charging capacity

Simple to operate

Ease of mobility

Facilitates connectivity for 90 of cellular phones

Less expensive

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 84

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 85: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Reduced man power

Low power consumption

It can offer emergency charging for 4sets of handsets synchronously

CHAPTER 15

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 85

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 86: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

DISADVANTAGES

OF THE PROJECT

Disadvantages

151 DISADVANTAGES OF THE PROJECT

It requires mains supply to work project

Due to limited charging channels till now there may be a possibility that

mobile phones of few brands cannot be connected for charging For this

purpose we have to use separate connectors for that specific brand differently

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 86

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 87: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

It does not bring a mobile from lsquodead to fully charged (full bars) just in 1

min

It does not have battery backup therefore it cannot be portable

CHAPTER 16

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 87

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 88: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPLICATIONS OF

THE PROJECT

Application

161 APPLICATIONS OF THE PROJECT

The coin based mobile phone charger is very useful to public for using coin to

charge for the mobile phone in any places

It is used for emergency charging purposes

It can be installed in malls railway stations bus stops and other public

places

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 88

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 89: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

The charger offers a unique revenue opportunity for a vast range of

businesses - from airports to pubs from universities to health clubs virtually

any location where there is a high footfall creating a large number of

potential users

It can be installed in offices and collages for pay charging facility

CHAPTER 17

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 89

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 90: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

FUTURE

DEVELOPMENT OF

THE PROJECT

FUTURE DEVELOPMENT OF THE PROJECT

171 FUTURE DEVELOPMENTOFTHE PROJECT

This project is very useful to people who are using mobile phone without charging

condition in public places

It will use with a stereo advertisement carrier that can display video advertisement

It will provide battery backup for make it portable

It will also provide SMS system in future

We can also increase the charging time by editing software of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 90

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 91: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 18

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 91

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 92: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

COST ANALYSIS

OF THE PROJECT

COST ANALYSIS OF THE PROJECT

181 COST ANALYSIS OF THE PROJECT

1811 Component list for power supply card

Footprint Quantity Designators Rate

Resistor

22K 1 R2 1

1K 1 R1 1

Capacitor

1000uf25V 1 C5 10

2200uf25V 1 C1 10

022uf 2 C6 C2 1

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 92

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 93: automatic coin operated mobile batery charger

Table 1811 Component list for power supply card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 2 C4 C3 1

IC

BRIDGE W10 2 BR2 BR1 10

L7812CV (TO-220) 1 U2 8

L7805CV (TO-220) 1 U1 8

Connector

CON PHO 2PIN 2 J3 J2 16

CON PHO 3PIN 1 J1 12

LED3mm red 2 L1 L2 15

Heat sink (TO-220) 2 16

Total 955

1812 Component list for battery charger card

Footprint Quantity Rate

Capacitor

2200uf25V 1 1000

022uf 4 100

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 93

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 94: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

01uf 4 100

IC

BRIDGE W10 1 500

L7805CV (TO-220) 4 3200

Connector

CON PHO 2PIN 1 800

Relimate 2 pin 1 400

relimate 3 pin 4 2000

Heat sink (TO-220) 4 1200

TOTAL 9300

1813 Component list for Relay card

Component Quantity Designators Rate ULN2003 1 U1 500RELAY RW-SH-112D 4 RL1 RL2 RL3 RL4 14000 RELIM-2 10 J2 J3 J4 J5 3300 J6 J7 J8 J9 J10 J11

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 94

Table 1812Component list for battery charger card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 95: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

RELIM-4 1 J1 700 16 pin ic socket 1 400

Total 18900

1814Component list for controller card

Component Quantity Designators Rate Capacitor 01uf 2 C5 C4 2001uf 4 C9 C8 C7 C6 40022pf 2 C3 C2 20033uf 1 C1 300 Resistor 10K 1 R1 10022K 1 R8 1001K 6 R7 R6 R5 R4 R3 R2 600 IC 4N33 1 U3 50089V51RD2FN 1 U1 12000MAX232CP 1 U2 2500 Connector Relimate 2 pin 9 SW1 SW2 SW3 SW4 SW5 4600 L4 L3 L2 L1 Relimate 3 pin 2 J3 J4 Relimate 4 pin 1 J2 2 pin terminal block 1 J1 800 LED LED 3mm green 1 L9 150LED 3mm red 1 L10 150LED 5mm green 4 800LED 5mm red 4 800 IC sockets

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 95

Table 1813Component list for relay card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 96: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

40 pin 1 100016 pin 1 5006 pin 1 400 Misc SIP resistor 1 RN1 200Crystal 110592MHz 1 XL1 500Tack switch 1 S1 200

total 27000

1815 Miscellaneous material

Material Quantity Rate

electronic item

Transformer

TXR1 0-9-15 1 20000

0-9 1A

0-15 100mA

TXR2 0-9 1 16500

0-9 1A

Proximity switch 1 20000

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 96

Table 1814Component list for microcontroller card

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 97: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Red push bottom 4 4000

Green push button 1 1000

Red led 5mm 4 800

Green led 5mm 4 800

Led holder 8 1600

Copper clad 2 4000

3 core cable 1 meter 1500

3 pin plug 1 3000

2 pin relimate wire 19 9000

3 pin relimate wire 5 3750

4 pin relimate wire 2 2000

mechanical items

Enclosure 1 25000

Acrylic sheet 2 X 1 30000

12mm cable gland 1 1000

Screw 3mm 33 2000

Screw 35mm 6 2400

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 97

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 98: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

10 mm spacers 100 1500

10mm insert to stud 50 10000

cable tie 2500

Total 162350

CHAPTER 19

APPENDIX

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 98

Table 1815Component list for miscellaneous material

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 99: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

APPENDIX

191 APPENDIX

1911 78xx IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 99

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 100: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1912 W10 datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 100

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 101: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1913 4n33 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 101

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 102: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Notes Indicates JEDEC registered data1 The current transfer ratio(ICIF) is the ratio of the detector collector current to the LED input current with VCE 10 V2 Pulse test pulse width = 300μs duty cycle 1048630104863020 3 For test circuit setup and waveforms refer to figure 74 IF adjusted to IC = 20 mA and IC = 07 mA rms5 The frequency at which IC is 3dB down from the 1 KHz value6 For this test LED pins 1 and 2 are common and phototransistor pins 45 and 6 are common

1914 MAX 232

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 102

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 103: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1915 ULN2003a IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 103

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 104: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 104

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 105: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

1916 89V51RD2 IC datasheet

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 105

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 106: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 106

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 107: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 107

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 108: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 108

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 109: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 109

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 110: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 20

CONCLUSION

CONCLUSION

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 110

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 111: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

201 CONCLUSION

The coin-operated mobile phone charger is already successfully installed in

hundreds of locations worldwide providing a unique service to the public and a source of

revenue for site providers The coin-operated mobile charger can be quickly and easily

installed in any business premises

The charger offers a unique revenue opportunity for a vast range of businesses ndash

from airports to pubs from universities to health clubs virtually any location where there is

a high footfall creating a large number of potential users

The charger can charge up to 4 different mobile phones simultaneously It will

extend low mobile phone talk time provide battery charging

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 111

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 112: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 21

IMAGES OF THE

PROJECT

Images of the project

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 112

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 113: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

211 IMAGES OF THE PROJECT

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 113

fig211 lsquoCoin operated mobile battery charger

Fig212 Circuit arrangement of coin operated mobile battery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 114: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig 216 Relay driver circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 114

Fig 213 Constant voltage battery charger circuit

Fig214 Power supply circuit

Fig215 Metal detector proximity switch

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 115: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig217 Microcontroller circuit

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 115

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 116: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

Fig228 coin operated mobile battery charger project presentation

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 116

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 117: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

CHAPTER 22

BIBILOGRAPHY

BIBLIOGRAPHY

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 117

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1
Page 118: automatic coin operated mobile batery charger

ldquoEMERGENCY COIN OPERATED MOBILE BATTERY CHARGERrdquo

221 BIBLIOGRAPHY

BOOKS

Microprocessor Architecture Programming Applications ndash Gaonkar CMOS Integrated Circuits Data Book ndash Sierra Optoelectronics Handbook ndash National Microprocessor Data Handbook Micro-Controller - Keneth Ayala Electronic Devices Applications amp Integrated Circuits-MathurKulshreshthaChadha Electronic Devices And Circuits - J B Gupta Electronics For You Magazine

INTERNET LINKS

wwwdiscoverprojectscom wwwgooglecom wwwdiscovercircuitscom wwwwikipediacom WWWdatasheetcatlogcom

PVPOLYTECHNIC SNDT University Mumbai-049 Page | 118

  • CHAPTER 1