Table of Contents

INTRODUCTION......................................................................................................... 1
BOOM-BARRIER:....................................................................................................... 3
Pictorial Representation of the Solution .................................................................13
Software configuration........................................................................................... 14
Benefits of the Solution.......................................................................................... 16
(i) Drawings:........................................................................................................... 17
(ii) System Documentation..................................................................................... 18
(5) QUALITY ASSURANCE:....................................................................................... 19
POWER SUPPLY :..................................................................................................... 20
SENSING CIRCUIT DIAGRAM.................................................................................... 21
WORKING OF CIRCUIT............................................................................................. 22
FUNDAMENTALS OF MOTOR................................................................................... 23
2. SPEED.............................................................................................................. 24
3. POWER............................................................................................................ 25
2. Motor Characteristics......................................................................................... 27
TORQUE/SPEED CURVES...................................................................................... 27
POWER/TORQUE and POWER/SPEED CURVES.....................................................30
SEMICONDUCTOR H-BRIDGES................................................................................31
CIRCUIT DIAGRAM................................................................................................... 34
WORKING OF CIRCUIT............................................................................................. 35
INFRARED TRANSMITTER AND RECEIVER CIRCUIT..................................................38
INTRODUCTION TO MICROCONTROLLER................................................................39
COMPLETE CIRCUIT DIAGRAM................................................................................. 44
Regulator............................................................................................................. 45
PARTS AND PRICE LIST............................................................................................ 48
BIBLOGRAPHY......................................................................................................... 52

INTRODUCTION

We propose to implement Project for Automatic Boom Barrier for your

Organization by supplying & Testing our RFID Hardware with International
Standard.

.. In a Manufacturing and Organizational kind of environment, RFID System

has significant potential in preventing the theft of Vehicle & Goods loaded in
the Vehicle from Company/Office and streamline time consuming operations
such as manual security check by guard at exit point of Company/Office.

.. The application developed is compatible with many international

standard RFID Readers i.e. - CSL, Motorola, Intermac, Marktrace, Impinj,
Alien and many more.
1

The foremost motive of our R&D is to develop an application that can be used
with all the RFID Readers of international standard. We have successfully
integrated and tested the Readers with our application.
We have plug and play system for RFID based Vehicle Identification and
Automatic data capturing from Weigh Bridge. The application works with all the
Boom Barriers and any of the Weigh Bridges.

The average log size in many parts of the world is getting smaller and it is
becoming increasingly time consuming and expensive to individually scale each
log

A credible Vehicle Identification and Automatic Weighing System is essential for

any industry for prohibiting the passage of unauthorized vehicles and for them who
are using the measurement of weight as a benchmark for sale of a product.

Manual Inaccuracy in payload weights can be created by either inaccurate gross

weights or variability between the tare weight of the truck and the actual weight of
the truck (gross weight minus payload) at the time of gross weighing.

It should also have an automated, efficient monitoring system that allows for
accurate vehicle identification as well as an easy measuring system for the load

BOOM-BARRIER:

DESIGN CONCEPT
Gate automation system proposed for CDRI Campus consist of Boom Barrier &
turnstile to restrict/ control/ monitor entry of vehicles and peoples to the
administrative and laboratory area of CD RI.
Boom Barriers are proposed to be installed on all the roads leading towards
administrative and laboratory area of CDRI Campus are as follows:
- Boom- barrier at main gate of the CDRI campus without access control
units
-Boom-barrier on other locations with access control units.
A rising boom barrier shall mean a vehicle access barrier that shall open in
case of an impulse with the use of a valid card. Vehicle of people authorized
by the CDRI Management shall enter into the restricted area.
Separate Boom Barriers are proposed for two and four wheel vehicle.
Boom-barriers which operate automatically utilize induction loops to detect
the approaching vehicles with the help of loop detector.
The turnstiles are proposed to be installed at all security checks of CDRI
campus to regulate the entry of pedestrians.
All the turnstile shall be operated through proximity card based access control
units. People with valid proximity cards can enter into the main
administrative building.

Provision for manual operation shall also be produced by the vendor.

Purchasers LAN network being laid by third party would be utilized to
extend the Boom Barrier and Turnstile connectivity to central server.
All boom Barriers/Turnstiles shall have connectivity to non- PoE port of
3

purchasers networking switches on LAN.

UPS Power supply for each Boom Barrier /Turnstile.

Tentative locations of Boom Barrier/Turnstile are indicated in the IP CCTV,
ACS , Boom Barriers and Turnstiles layout drawing enclosed with this
tender.
JBs , power supply etc. shall be in IP-66 housing.

Supply, installation, testing, connecting and commissioning a high quality

fast-acting gate automation system at CDRI campus.
The entire system should be as per BOQ, drawings and technical
specifications mention under this part.

 The price coated by the vendor should include all the expenses incurred in
commissioning of gate automation System, comprising of boom barrier and
electromechanical turnstiles.
The boom barrier and turnstile shall function in integration with proximity
card based access control units.
Boom barrier shall comprise of boom, motor, loop detector, control pillar
for access control complete with all other accessories and providing of
supervisory specialists and technicians at the site to assist in all phases of
system installation, start up and commissioning.
The scope of work includes making of foundation, loop installation for barrier
including all work of laying of cable.
Control pillar to house card reader IP 44 protections and polycarbonate sheet
for card reader.
Canopy or shed for turnstile to protect from direct rain and sunlight.
Cat 6 cable/fiber cable connectivity with all required hardware upto
purchasers networking switches of LAN, locations of networking switches
in CDRI campus are indicated in the list. enclosed with this tender
docoments.
230 volts AC Power supply distribution from UPS to each location of Boom
Barrier/Turnstiles along with DBs ,JBs, cabling work with required
accessories.

Power supply unit as required for Boom Barrier/Turnstiles.

Integrated testing and commissioning of Boom Barriers and Turnstiles on
LAN being provided by the third party in CDRI campus.

Training & handing over of all materials, equipment and appliances

Any other items/accessories required for
commissioning of Boom Barriers and Turnstiles.
5

installation,testing

and

We Proposes a Passive RFID based Vehicle Management Solution and Automatic

Data Capturing from Weighbridge, providing a complete industrial solution.
According to the need, size and scale of the industry we can propose the robust
RFID Readers best suited for the implementation.
This is achieved as the application developed is capable to trigger more than 10
different RFID Readers.
Now each Weighbridge will have boom barriers, and entrance of Weighbridge
equipped with RFID readers and circular antennas.

Each vehicle has a passive tag, which is applied inside the windshield.
The windshield tag is a high performance tag that is ideal for plastic and glass.

2) ACCESS CONTROL SYSTEM ( BARRIER):

7

(i) DESIGN CONCEPT

Access Control System is designed for the entrances and corridors of
main buildings of CDRI campus as follows:
-Entrance of the Administration block
- Entrance of the Computer hub
- Front and back entrances of the laboratories and connecting
corridors
- Entrance of the Special Equipment and lab engineering services
- Entrance of the Chemical Storage
- Front and back entrance of the Animal House
- Hospital dispensary for
time attendance - For all
boom-barriers
except
main gate - For all
turnstiles except main
gate
Access control system shall be based on proximity card technology in
order to restrict the entry of unauthorized people.

Proximity Cards will be issued to the staff members, students and

visitors of CD RI.
The Access control system shall provide access through the protected
doors for only those card holders whose entry is allowed.
The access controller shall provide the status of each card, reader and
control door.
Purchasers LAN network being laid by third party would be
utilized to extend the BARRIER connectivity to central server.
All controller/reader of BARRIER shall have connectivity to nonPoE port of purchasers networking switches on LAN.

UPS Power supply for each BARRIER.

8

 Tentative locations of BARRIER are indicated in the IP CCTV,

BARRIER , Boom Barriers and Turnstiles layout drawing
enclosed with this tender.
All outdoor items shall be in IP-66 housing.
The BARRIER shall be a software-based solution and shall be flexible
enough to work with multiple Hardware providers. The software shall
include all the features /requirement for BARRIER as specified in the
specifications
The BARRIER shall be based on TCP/IP network protocol and shall
communicate with Ethernet ready, TCP/IP based components.
The BARRIER software shall be capable of running on windows or
Linux server platforms with full- feature operation.
The Controller shall be capable of operating independently if
communications with the Host Server is lost.
Provide supervisory specialists and technicians at the job to assist in
all phases of system installation, start up and commissioning.
Cat 6cable/fiber cable connectivity with all required hardware upto
purchasers networking switches of LAN, locations of networking
switches in CDRI campus are indicated in the list. enclosed with this
tender documents.
230 volts AC Power supply distribution from UPS to each location of
BARRIER along with DBs ,JBs, cabling work etc. with required
accessories.

Power supply unit as required for BARRIER.

Integrated testing and commissioning of BARRIER on LAN being
provided by the third party in CDRI campus

Training & handing over of all materials, equipment and appliances

Any other items/accessories required for installation, testing and
commissioning of Access Control system.
9

 No extra cost shall be paid for any miscellaneous items, if required to

complete the work as per design concept.

10

Fig: - A Container Truck Moving on the WEIGHBRIDGE mounted RFID

Reader Capturing the Data.

11

As soon as the RFID Reader reads the tags affixed on the trucks its number plate
will be automatically displayed on the system software (i.e. client PC).
Also the net weight of the load carried by the vehicles can be displayed against
respective vehicles in the software.
The RFID system can be integrated with software systems for billing, reporting, and
revenue collection, that provides even greater cost and time efficiency to operators
Rollout of System is quick and easy and can be used in conjunction with existing
systems.

Pictorial Representation of the Solution ..

12

13

Software configuration

The system can be connected to a central host or be used in a stand-alone

configuration.

14

The Reader has an internal database

to which the ID-tags unique identities can be
uploaded though software user interface.
The reader checks the identity and accepts/rejects
the ID-tag based on ID-tag status and software will
also interacts with the weighbridge and records the
net weight of the Vehicle.
This is a cost effective solution for remote
installations, where it is difficult or expensive with
cable connections to a central host.

15

Benefits of the Solution

Our System will eliminate the repetitive job of staffs at weigh station.
He does not need to rekey truck license plate number every time when the
truck is on the weighbridge.
16

 Simultaneously, this can protect the problem of cloning truck.

Additionally the RFID and weighing program is integrated with weighbridge.
As a result the problem of duplicating or artificial weighing can be removed
completely.
Delivery materials through weighbridge requires many operation steps
starting from queuing, registration for weighing ,pre and post loading.

These process are operated manually.

At the end of weighing , it is needed to repeat doing data entry into ERP
system for further process.
These operations are not only waste of time but also tend to have high error
rate because of human intervention.
This also opens room for man made fraud which can cause financial loss to
any enterprises.

(i) Drawings:

The system supplier shall submit all shop drawings, and bill of materials for
approval /reference.

Drawings shall be submitted in standard sizes as indicated

Four complete sets (copies) of submittal drawings shall be provided.
17

Drawings shall be available on CD-ROM.

CCTV, Access Control System, Boom Barrier and Turnstile layout drawing
( A1 size)
Installation drawing for each item ( A3 size )
Bill of Materials ( A4 size)
Cable connectivity drawings and cable schedule. ( A3 Size)
Power distribution scheme ( A3 size)
Specifications and data sheet for each item (A4 size)
List of software and software licenses,(A4 size).
Test certificates, Internal test reports etc.

(ii) System Documentation

System configuration diagrams in simplified block format.

18

 Manufacturer's instructions and drawings for installation, maintenance, and

operation of all purchased items.
Overall system operation and maintenance instructionsincluding preventive
maintenance and troubleshooting instructions.
A list of all functions available and a sample of function block programming
that shall be part of delivered system.
Shop drawings of card reader stand, canopy/shed as approved by consultant.
Test certificates and internal test reports for each item
Quality Assurance Plan
Operation and maintenance manuals.

19

(5) QUALITY ASSURANCE:

The entire system shall be installed and commissioned from a single vendor to
assure reliability and continued service.
The vendor shall be required to train and instruct client's personnel in the
correct use, operation and supervision of the system, preferably prior to the
handing over of the project.
The supplier shall be responsible for inspection and Quality Assurance (QA) for
all materials and workmanship furnished.

20

POWER SUPPLY :
230 V + 10 % , 50 Hz + 5% shall be made available for UPS input. Bidders scope shall include
complete power distribution for IP CCTV system,Access Control system , Boom Barriers and
Turnstiles, including complete cabling work, DBs and required electrical accessories with suitable
protection devices from UPS (in bidders scope) and UPS output to IP CCTV cameras , Access
control devices, Boom Barriers and Turnstiles.

Colour sensor is an interesting project for hobbyists. The cir- cuit can sense eight colours,
i.e. blue, green and red (primary colours); magenta, yellow and cyan (secondary colours);
and black and white. The circuit is based on the fundamentals of optics and digital
electronics. The object whose colour is required to be detected should be placed in front
of the system. The light rays reflected from the object will fall on the three convex lenses
which are fixed in front of the three photo diodes. The convex lenses are used to
converge light rays. This helps to increase the sensitivity of photo diodes. Blue, green
and red glass plates (filters) are fixed in front of photo diode 1, photo diode 2 and photo
diode 3 respectively. When reflected light rays from the object fall on the gadget, the
coloured filter glass plates determine which of the photo diodes would get triggered. The
circuit makes use of only AND gates and NOT gates.

When a primary coloured light ray falls on the system, the glass plate corresponding to
that primary colour will allow that specific light to pass through. But the other two glass
plates will not allow any light to pass through. Thus only one LDR will get triggered and
the gate output corresponding to that photo diode will become logic 1 to indicate which
colour it is. Similarly, when a secondary coloured light ray falls on the system, the two
primary glass plates corres- ponding to the mixed colour will allow that light to pass
through while the remaining one will not allow any light ray to pass through it. As a result
two of the photo diodes get triggered and the gate output corresponding to these will
become logic 1 and indicate which colour it is.

21

SENSING CIRCUIT DIAGRAM

22

WORKING OF

CIRCUIT

23

FUNDAMENTALS OF MOTOR
24

There are different kinds of D.C. motors, but they all work on the same principles. To understand
what goes on inside a motor, here is an example.

When a permanent magnet is positioned around a loop of wire that is hooked up to a D.C. power
source, we have the basics of a D.C. motor. In order to make the loop of wire spin, we have to
connect a battery or DC power supply between its ends, and support it so it can spin about its
axis. To allow the rotor to turn without twisting the wires, the ends of the wire loop are connected
to a set of contacts called the commutator, which rubs against a set of conductors called the
brushes. The brushes make electrical contact with the commutator as it spins, and are
connected to the positive and negative leads of the power source, allowing electricity to flow
through the loop. The electricity flowing through the loop creates a magnetic field that interacts
with the magnetic field of the permanent magnet to make the loop spin.
25

The DC motor used in this project is Direct Current permanent magnet motors operated at a
constant voltage. Motor characteristics vary considerably from type to type, and their performance
characteristics can be altered by the way electrical power is supplied. can be quite different than
those covered here. Few physical parameters associated with DC motors are

2. SPEED

Speed (Angular Velocity)

The rate of rotation around an axis usually

in radians or revolutions per second or per minute

expressed

Motors are devices that convert electrical energy into mechanical energy. The D.C. motors that
we have been dealing with here convert electrical energy into rotational energy. That rotational
energy is then used to lift things, propel things, turn things, etc. When we supply the specified
voltage to a motor, it rotates the output shaft at some speed. This rotational speed or angular

radians/second
{rad/s},
revolutions/second {rps}, or revolutions/minute {rpm}.
velocity,

is

typically

measured

in

When performing calculations, be sure to use consistent units. In the English system,
calculations should be done in degrees/second, and radians/sec for SI calculations.
26

NOTE:
1
revolution
1
revolution
1
radian
1 = (/180) radians

=
(2*)

=
=

360
radians
(180/)

From the angular velocity, , we can find the tangential velocity of a point anywhere on the
rotating body through the equation tangential velocity,
v= r* , where r is the distance from the axis of rotation. This relation can be used to compute
the steady state (constant speed - no acceleration) speed of a vehicle if the radius and angular
velocity of a wheel is known, or a winch winds up the linear speed of a rope as it.
3. POWER
Motive
a. Ability to act or produce an effect

Power

b. A source or means of supplying energy; especially: ELECTRICITY

c. MOTIVE POWER the time rate at which work is done or energy emitted or transferred
Power in Rotational Motion
When you pedal a bicycle, you apply forces to a rotating body and do work on it. Similar
things happen in real-life situations, such as a rotating motor shaft driving a power tool or a car
engine propelling the vehicle. We can express this work in terms of torque and an angular
displacement...
What about the power associated with work done by a torque acting on a rotating body? dW/dt is
the rate of doing work, or power P. When a torque T (with respect to the axis of rotation) acts on
a body that rotates with angular velocity W, its power (rate of doing work) is the product of the
torque and angular velocity. This is the analog of the relation P = Fv for particle motion.

27

Power

in

rotational

motion

can

be

written

as:

UNITS of POWER
SI
Watts
newton-meters

English

per

1
W
=
1
W
=
1 W = 1.341E-03 hp

second
1
0.738

{W} foot-pounds
{Nm/s} horsepower

per

Nm/s 1
ftlb/s
=
ftlb/s 1 ftlb/s = 1.356 W

second

1.818E-03

{ftlb/s}
{hp}
hp

2. Motor Characteristics
TORQUE/SPEED CURVES
In order to effectively design with D.C. motors, it is necessary to understand their characteristic
curves. For every motor, there is a specific Torque/Speed curve and Power curve.
28

The graph above shows a torque/speed curve of a typical D.C. motor. Note that torque is
inversely proportioal to the speed of the output shaft. In other words, there is a tradeoff between
how much torque a motor delivers, and how fast the output shaft spins. Motor characteristics are
frequently given as two points on this graph:

The stall torque, , represents the point on the graph at which the torque is a maximum,
but the shaft is not rotating.

The no load speed,

, is the maximum output speed of the motor (when no torque is

applied to the output shaft).

The curve is then approximated by connecting these two points with a line, whose equation can
be written in terms of torque or angular velocity as equations 3) and 4):

The linear model of a D.C. motor torque/speed curve is a very good approximation. The
torque/speed curves shown below are actual curves for the green maxon motor. One is a plot of
29

empirical data, and the other was plotted mechanically using a device. Note that the characteristic
torque/speed curve for this motor is quite linear.

This is generally true as long as the curve represents the direct output of the motor, or a simple
gear reduced output. If the specifications are given as two points, it is safe to assume a linear
curve.

Recall that earlier we defined power as the product of torque and angular velocity. This
corresponds to the area of a rectangle under the torque/speed curve with one corner at the origin
and another corner at a point on the curve (see figures below). Due to the linear inverse
relationship between torque and speed, the maximum power occurs at the point where,

, and

30

31

POWER/TORQUE and POWER/SPEED CURVES

32

By substituting equations 3 and 4 (torque and speed) into equation 2 (Power), we see that the
power curves for a D.C. motor with respect to both speed and torque are quadratics, as shown in
equations
5
and
6.

From these equations, we again find that maximum output power occurs at

, and

respectively

SEMICONDUCTOR H-BRIDGES
we can better control our motor by using transistors or Field Effect Transistors (FETs). Most of
what we have discussed about the relays H-Bridge is true of these circuits. You don't need diodes
that were across the relay coils now. You should use diodes across your transistors though. See
the following diagram showing how they are connected. These solid state circuits provide power
and ground connections to the motor, as did the relay circuits. The high side drivers need to be
current "sources" which is what PNP transistors and P-channel FETs are good at. The low side
drivers need to be current "sinks" which is what NPN transistors and N-channel FETs are good at.

33

If you turn on the two upper circuits, the motor resists turning, so you effectively have a breaking
mechanism. The same is true if you turn on both of the lower circuits. This is because the motor is
a generator and when it turns it generates a voltage. If the terminals of the motor are connected
(shorted), then the voltage generated counteracts the motors freedom to turn. It is as if you are
applying a similar but opposite voltage to the one generated by the motor being turned. Vis--vis,
it acts like a brake. To be nice to your transistors, you should add diodes to catch the back voltage
that is generated by the motor's coil when the power is switched on and off. This flyback voltage
can be many times higher than the supply voltage! If you don't use diodes, you could burn out
your transistors.

34

Transistors, being a semiconductor device, will have some resistance, which causes them to get
hot when conducting much current. This is called not being able to sink or source very much
power, i.e.: Not able to provide much current from ground or from plus voltage.
Mosfets are much more efficient, they can provide much more current and not get as hot. They
usually have the flyback diodes built in so you don't need the diodes anymore. This helps guard
against flyback voltage frying your MCU. To use Mosfets in an H-Bridge, you need P-Channel
Mosfets on top because they can "source" power, and N-Channel Mosfets on the bottom because
then can "sink" power. N-Channel Mosfets are much cheaper than P-Channel Mosfets, but NChannel Mosfets used to source power require about 7 volts more than the supply voltage, to turn
on. As a result, some people manage to use N-Channel Mosfets, on top of the H-Bridge, by using
cleaver circuits to overcome the breakdown voltage.
It is important that the four quadrants of the H-Bridgecircuits be turned on and off properly. When
there is a path between the positive and ground side of the H-Bridge, other than through the
motor, a condition exists called "shoot through". This is basically a direct short of the power supply
and can cause semiconductors to become ballistic, in circuits with large currents flowing. There
are H-bridge chips available that are much easier, and safer, to use than designing your own HBridge circuit.

35

H-Bridge Devices
The L 293 has 2 H-Bridges, can provide about 1 amp to each and occasional peak loads to 2
amps. Motors typically controlled with this controller are near the size of a 35 mm film plastic
canister.
The L298 has 2 h-bridges on board, can handle 1amp and peak current draws to about 3amps.
You often see motors between the size a of 35 mm film plastic canister and a coke can, driven by
this type H-Bridge. The LMD18200 has one h-bridge on board, can handle about 2 or 3 amps and
can handle a peak of about 6 amps. This H-Bridge chip can usually handle an average motor
about the size of a coke. There are several more commercially designed H-Bridge chips as well

36

CIRCUIT DIAGRAM

37

38

WORKING OF CIRCUIT

This circuit drives small DC motors up to about 100 watts or 5 amps or 40 volts, whichever comes
first. Using bigger parts could make it more powerful. Using a real H-bridge IC makes sense for
this size of motor, but hobbyists love to do it themselves, and I thought it was about time to show
a tested
H-bridge motor driver that didn't use exotic parts.
Operation is simple. Motor power is required, 6 to 40 volts DC. There are two logic level
compatible inputs, A and B, and two outputs, A and B. If input A is brought high, output A goes
high and output B goes low. The motor goes in one direction. If input B is driven, the opposite
happens and the motor runs in the opposite direction. If both inputs are low, the motor is not
driven and can freely "coast", and the circuit consumes no power. If both inputs are brought high,
the motor is shorted and braking occurs. This is a special feature not common to most discrete Hbridge designs, drive both inputs in most
H-bridges and they self-destruct. About 0.05 amps is consumed in this state
To do PWM (pulse width modulation) speed control, you need to provide PWM pulses. PWM is
applied to one input or the other based on direction desired, and the other input is held either high
(locked rotor) or low (float). Depending on the frequency of PWM and the desired reaction of
the motor, one or the other may work better for you. Holding the non-PWM input low generally
works best for low frequency PWM, and holding the non-PWM input high generally works best at
high frequencies, but is not efficient and produces a lot of heat, especially with these Darlington,
so locked rotor is not recommended for this circuit.
Truth table:
Input | output
A| B | A| B
--------------0 0 | float

39

1 0|1 0
0 1|0 1
1 1|1 1

Performance:
Please reference the accompanying schematic diagram. The circuit uses Darlington power
transistors to reduce cost. Forward losses are typically 1 to 2 volts, and since the current must
pass through two transistors, expect losses to total up to 4 volts at maximum current. The 4
Darlington transistors need to be heat sink based on your expected current and duty cycle.
PWM operation over 3 kHz wills likely lead to high losses and more heat dissipation, due to the
simplicity of the circuit and the construction of Darlington transistors. You might get away with
higher frequencies if you put a 1K resistor emitter-base on each TIP12x transistor. I prefer to go
with very low frequencies, 50 to 300Hz.
Not shown in the schematic are the internal pinch-off resistors (5K and 150 ohms) and the
damper diode that are built into all TIP12x series transistors. If you build your own variation of the
circuit with other parts, include these necessary parts. To the right is a picture of the internals of
the TIP12x transistors.

Operation with logic signals greater than the motor supply voltage is allowed and
absorbed by R7 and R8. The circuit is really intended to be operated with CMOS logic
levels, logic high being about 4 volts.
If you live in the U.S., expect the TIP120 and TIP125 transistors to cost about $0.50 and
the very common and generic "quad-2" PN2222A to cost about $0.10. An inexpensive
40

source for hobbyist-grade parts like these is Jameco Electronics. At low duty cycles,
currents up to the 8 amp rated peak of the transistors is allowed, but there is no current
limiting in this circuit, so it would be unwise to use this circuit to drive a motor that
consumes more than 5 amps when stalled.

Notes on circuit assembly:

Transistors Q1, 2, 3 and 4 must be heat sunk. Insulators should be used, or two separate
heat sinks isolated from each other and the rest of the world. Note that Q1 and Q3 are
grouped together and share common collectors and can share a heat sink. The same is
true for Q2 and Q4.
Operation over 3 kHz will lead to higher losses. If it is required to run at higher frequency,
additional pinch-off resistors can be added to Q1,2,3 and 4, supplementing the internal
resistors. A good value would be 1k, and the resistors should be soldered from base to
emitter.
To reduce RF emissions, keep the wires between the circuit and the motor short. No
freewheel diodes are required; they are internal to the TIP series Darlington transistors.
Drive the circuit from 5-volt logic. Drive levels higher than 5 volts will tend to heat up R1
and 2. This is OK for short periods of time.
Power supply voltage is 5 to 40 volts. Output current up to 5 amps is allowed if the power
supply voltage is 18 volts or less. Peak current must be kept below 8 amps at all times.
There is no current limiting in this circuit. Reversing a motor at full speed can cause it to
draw huge currents, understand your load to avoid damage. There are higher powered
devices in the TIP series of Darlington transistors; these can be substituted if needed.
Look at the TIP140 and TIP145, please note they are in a bigger package and dont fit the
PC board layout.

41

INFRARED TRANSMITTER AND RECEIVER CIRCUIT

42

INTRODUCTION TO MICROCONTROLLER
43

INSTRUCTION SETS

INSTRUCTION SET SUMMARY

Each PIC16CXX instruction is a 14-bit word divided into an OPCODE which specifies the
instruction type and one or more operands which further specify the operation of the instruction.
The PIC16CXX instruction set summary in Table 13-2 lists byte-oriented, bit-oriented, and
literal and control operations. Table 13-1 shows the opcode field descriptions.
For byte-oriented instructions, f represents a file register designator and d represents a
destination designator.
The file register designator specifies which file register is to be used by the instruction.
The destination designator specifies where the result of the operation is to be placed. If d is zero,
the result is placed in the W register. If d is one, the result is placed in the file register specified in
the instruction.
For bit-oriented instructions, b represents a bit field designator which selects the number of the
bit affected by the operation, while f represents the number of the file in which the bit is located.
For literal and control operations, k represents an eight or eleven bit constant or literal value.

TABLE 13-1:

OPCODE FIELD
DESCRIPTIONS

44

The instruction set is highly orthogonal and is grouped into three basic categories:
Byte-oriented operations
Bit-oriented operations
Literal and control operations
All instructions are executed within one single instruction cycle, unless a conditional test is true or
the program counter is changed as a result of an instruction.
In this case, the execution takes two instruction cycles with the second cycle executed as a NOP.
One instruction cycle consists of four oscillator periods. Thus, for an oscillator frequency of 4
MHz, the normal instruction execution time is 1 ms. If a conditional test is true or the program
counter is changed as a result of an instruction, the instruction execution time is 2 ms. Table 13-2
lists the instructions recognized by the MPASM assembler.
Figure 13-1 shows the general formats that the instructions can have.

All examples use the following format to represent a hexadecimal number:

0xhh
45

where h signifies a hexadecimal digit.

FIGURE 13-1: GENERAL FORMAT FOR INSTRUCTIONS

A description of each instruction is available in the

PICmicro Mid-Range Reference Manual, (DS33023)

46

TABLE 13-2: PIC16CXXX INSTRUCTION SET

47

Note 1: When an I/O register is modified as a function of itself ( e.g., MOVF PORTB, 1), the
value used will be that value present on the pins themselves. For example, if the data latch is 1
for a pin configured as input and is driven low by an external device, the data will be written back
with a 0.
2: If this instruction is executed on the TMR0 register (and, where applicable, d = 1), the
prescaler will be cleared if assigned to the Timer0 Module.
3: If Program Counter (PC) is modified or a conditional test is true, the instruction requires two
cycles. The second cycle is executed as a NOP.

Description:

The eight bit literal 'k' is loaded into W register. The dont cares will
assemble as 0s.

48

COMPLETE CIRCUIT DIAGRAM

49

50

POWER SUPPLY

POWER SUPPLY CIRCUIT DIAGRAM

51

Voltage

regulator

PhotographRapid Electronics

Regulator
Voltage regulator ICs are available with fixed (typically 5, 12 and 15V) or variable output voltages.
They are also rated by the maximum current they can pass. Negative voltage regulators are
available, mainly for use in dual supplies. Most regulators include some automatic protection from
excessive current ('overload protection') and overheating ('thermal protection').
Many of the fixed voltage regulator ICs have 3 leads and look like power transistors, such as the
7805 +5V 1A regulator shown on the right. They include a hole for attaching a heatsink if
necessary.
Please

see

the

website

for

more

52

information

about

voltage

regulator

ICs.

zener
a = anode, k = cathode

diode

Zener diode regulator

For low current power supplies a simple voltage regulator can be made with a resistor and a
zener diode connected in reverse as shown in the diagram. Zener diodes are rated by their
breakdown voltage Vz and maximum power Pz (typically 400mW or 1.3W).
The resistor limits the current (like an LED resistor). The current through the resistor is constant,
so when there is no output current all the current flows through the zener diode and its power
rating Pz must be large enough to withstand this.
Please see the Diodes page for more information about zener diodes.
Choosing a zener diode and resistor:
1. The zener voltage Vz is the output voltage required
2. The

input

voltage

Vs

must

be

few

volts

greater

than

(this is to allow for small fluctuations in Vs due to ripple)

3. The maximum current Imax is the output current required plus 10%
4. The zener power Pz is determined by the maximum current: Pz > Vz Imax
5. The resistor resistance: R = (Vs - Vz) / Imax
6. The resistor power rating: P > (Vs - Vz) Imax
Example: output voltage required is 5V, output current required is 60mA.

1. Vz = 4.7V (nearest value available)

2. Vs = 8V (it must be a few volts greater than Vz)

53

Vz

3. Imax = 66mA (output current plus 10%)

4. Pz > 4.7V 66mA = 310mW, choose Pz = 400mW
5. R = (8V - 4.7V) / 66mA = 0.05k

= 50 , choose R = 47

6. Resistor power rating P > (8V - 4.7V) 66mA = 218mW, choose P = 0.5W

54

PARTS AND PRICE LIST

SNo.

Part No.

1.

PIC16F72

2.

TIP 122

3.

ULN2803

4.

TIP 127

5.

1N4007

6.

LM7805

7.

1000uf/25v

8.

10k
1k
4.7
820R
3.9K

9.

1N514

10.

T1

11.

PCB

12.

12x15

13.

DM12B500

14.

4 inch wheels

15.
16.

LM324

55

17.

NE555

18.

BC 547

19.

MT42

20.
21.

TL91

22.

TL92

23.

TSOP1738

24.

IR218

56

57

58

59

BIBLOGRAPHY

1. Bakkalbasi, O. and McGinnis, L.F., 1988, "ABC's of Preliminary In-House Planning and
Analysis of AGVS Applications," Proceedings of AGVS'88, MHI, Cincinnati, OH,
September 27-28.
2. Bartholdi, J.J. and Platzman, L.K., 1989, "Decentralized Control of Automated Guided
Vehicles on a Simple Loop," IIE Transactions, vol. 21, no. 1, pp. 76-81.
3. Baumgartner, E.T. and Skaar, S.B., 1994, "An Autonomous Vision-based Mobile Robot,"
IEEE Transactions on Automatic Control, vol. 39, pp. 493-502.
4. Biemans, F.P.M. and Vissers, C.A., 1989, "Reference Model for Manufacturing Planning
and Control Systems," Journal of Manufacturing Systems, vol. 8, no. 1, pp. 35-46.
5. Bohlander, R.A. and Heider, W., 1988, "Control Considerations When Planning AGVS
Installations," Proceedings of AGVS'88, MHI, Cincinnati, OH, September.
6. Bozer, Y.A., and Srinivasan, M.M., 1991, "Tandem Configurations for Automated Guided
Vehicle Systems and the Analysis of Single-Vehicle Loops," IIE Transactions, vol. 23, no.
1, pp. 72-82.

60