BIKE GEAR INDICATOR

CHAPTER 1: INTRODUCTION

Chapter 1
INTRODUCTION

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1.1

CHAPTER 1: INTRODUCTION

INTRODUCTION:
The main objective of this chapter is to give the ideas about the whole project. This

chapter contains of several subtopics that contains of project overview, the objective, scope,
the methodology and the summary of the thesis. This chapter is also including of explanation
of the implementation process of the project.

1.2

PROJECT OVERVIEW:

The project consists of a main circuit that includes a LCD display indicator, two Hall
sensors attached to the bike frame, and a small magnet placed on the gear shift lever. It
operation depends entirely on the gear shift lever movement instead of connecting to
speedometer and tachometer sensors, making this its main advantage. The signals of the two
hall sensors are read by the AVR ATmeag8 microcontroller. The current gear is stored in
EEPROM even if the motor is turned OFF. This will be restored when the device is turned
ON again.

1.3 OBJECTIVE AND MOTIVATION:

The primary objective of our project is to provide a bike gear shift indicating device
which enables a rider to identify the gear shift level with ease. This is quite a simple
implementation compared to some of the other vehicle information displays.
The use of technology in different areas led us to think for a new and different project.
During our research for project topic, we got to know about gear indication, its use and scope.
We tried to test it via bread board if it can be made or not. The result it gave was correct. This
made us work on gear indication project.

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CHAPTER 1: INTRODUCTION

1.4 FLOW CHART AND ITS WORKING:

Hall Sensor

Magnetic Field
Sense from
Gear lever

No

Sensing On?

Yes
Sense Level
Down

Up

Gear level
decreased by
-1

Gear level
increased by
+1

Microcontroller
Operation
Crystal
Oscillator
(16 MHz
Freq.
Generation

LCD Display

Fig 1.1Flow Chart

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CHAPTER 1: INTRODUCTION

There are two hall sensors in the project, Bike Gear Indicator. They are up Sensor
and down sensor. When there is an increase in Gear Level, the count increases by +1
and when there is a increase in Gear Level, count decreases by -1. In motorcycles,
there are gear levers. When the gear levers are in motion, they create magnetic field
and those magnetic fields are captured and sensed by the two hall sensors depending
upon down gear shift or up gear shift. The fields generated are in ac (alternative
current) form. Hence a bridge rectifier is used to convert it into dc (direct current)
form upto 5 Volts. This along with the sensor output is given to the microcontroller.
A crystal oscillator is connected to the microcontroller which generates 16 MHz
frequency required for the operation. The whole operation is performed in the
microcontroller. A 16*2 LCD display is connected to the microcontroller which
indicates the gear level as projects output.

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CHAPTER 1: INTRODUCTION

Chapter 2
LIST OF COMPONENTS

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CHAPTER 1: INTRODUCTION

2.1 CIRCUIT DIAGRAM:

Fig 2.1 Circuit diagram of Bike Gear Indicator

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CHAPTER 1: INTRODUCTION

2.2 List of Component:

I.
II.

Hall sensor US5881LUA

LCD Display

III.

Voltage regulator 7805

IV.

Crystal Oscillator

V.
VI.
VII.

Bridge Rectifier
PCB
Resistors

VIII.

Capacitors

IX.

9V Battery

2.2.1 Hall Sensor US5881LUA:

A Hall sensor is a transducer that varies its output voltage in response to a magnetic
field. Hall Effect sensors are used for proximity switching, positioning, speed detection, and
current sensing applications.

Fig 2.2 Hall sensor

In its simplest form, the sensor operates as an analog transducer, directly returning a
voltage. With a known magnetic field, its distance from the Hall plate can be determined.
Using groups of sensors, the relative position of the magnet can be deduced.

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CHAPTER 1: INTRODUCTION

Frequently, a Hall sensor is combined with circuitry that allows the device to act in a
digital (on/off) mode, and may be called a switch in this configuration. Commonly seen in
industrial applications such as the pictured pneumatic cylinder, they are also used in
consumer equipment; for example some computer printers use them to detect missing paper
and open covers. When high reliability is required, they are used in keyboards.
The US5881 is a unipolar Hall Effect sensor IC fabricated from mixed signal CMOS
technology. It incorporates advanced chopper stabilization techniques to provide accurate and
stable magnetic switch points. There are many applications for this sensor in addition to those
listed above. The design, specifications and performance have been optimized for
applications of solid state switches

2.2.1.1 PIN Diagram:

Fig 2.3 Pin Diagram of Hall Sensor

2.2.2 LCD Display:

Fig 2.4LCD Display

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CHAPTER 1: INTRODUCTION

A liquid-crystal display (LCD) is a flat panel display, electronic visual display,

or video display that uses the light modulating properties of liquid crystals. Liquid crystals do
not emit light directly. LCDs are used in a wide range of applications including computer
monitors, televisions, instrument panels, aircraft cockpit displays, and signage. They are
common

in

consumer

devices

such

as

DVD

players,

gaming

devices, clocks, watches, calculators, and telephones, and have replaced cathode ray
tube (CRT) displays in most applications. They are available in a wider range of screen sizes
than CRT and plasma displays, and since they do not use phosphors, they do not suffer image
burn-in. LCDs are, however, susceptible to image persistence.

2.2.3 Voltage Regulator 7805:

The 78xx (sometimes LM78xx) is a family of self-contained fixed linear voltage
regulator integrated circuits. The 78xx family is commonly used in electronic circuits
requiring a regulated power supply due to their ease-of-use and low cost. For ICs within the
family, the xx is replaced with two digits, indicating the output voltage (for example, the 7805
has a 5 volt output, while the 7812 produces 12 volts). The 78xx line is positive voltage
regulators: they produce a voltage that is positive relative to a common ground. There is a
related line of 79xx devices which are complementary negative voltage regulators. 78xx and
79xx ICs can be used in combination to provide positive and negative supply voltages in the
same circuit.

Fig 2.5Pins diagram of voltage regulator IC

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CHAPTER 1: INTRODUCTION

2.2.3.1 Pin Description:

PIN

TYPE

DESCRIPTION

Name

NO.

Input

Supply Input

Common

Ground

Output

Supply Input

Table No. 2.1 Pin description of 7805B

2.2.4 Crystal Oscillator:

Fig 2.6Crystal Oscillator

A crystal

oscillator is

an electronic

oscillator circuit

that

uses

the

mechanical resonance of a vibrating crystal of piezoelectric material to create an electrical

signal with a very precise frequency. This frequency is commonly used to keep track of time
(as in quartz wristwatches), to provide a stable clock signal for digital integrated circuits, and
to stabilize frequencies for radio transmitters and receivers. The most common type of
piezoelectric resonator used is the quartz crystal, so oscillator circuits incorporating them
became known as crystal oscillators

2.2.5 Bridge Rectifier:

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CHAPTER 1: INTRODUCTION

Fig 2.7Bridge Rectifier

A diode

bridge is

an

arrangement

of

four

(or

more) diodes in

a bridge

circuit configuration that provides the same polarity of output for either polarity of input.
When used in its most common application, for conversion of an alternating
current (AC) input into a direct current (DC) output, it is known as a bridge rectifier. A bridge
rectifier provides full-wave rectification from a two-wire AC input, resulting in lower cost
and weight as compared to a rectifier with a 3-wire input from a transformer with a centertapped secondary winding.
The essential feature of a diode bridge is that the polarity of the output is the same
regardless of the polarity at the input.

2.2.6 PCB:

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CHAPTER 1: INTRODUCTION

Fig 2.8PCB
Printed circuit boards are electronic circuits boards created for mounting electronic
components on a nonconductive board, and for creating conductive connections between
them. The boards are made from glass reinforced plastic with copper tracks in the place of
wires. Components are fixed in position by drilling holes through the board, locating the
components and then soldering them in place. The copper tracks link the components
together forming a circuit
A PCB allows signals and power to be routed between physical devices. Solder is the
metal that makes the electrical connections between the surface of the PCB and the electronic
components. Being metal, solder also serves as a strong mechanical adhesive.

2.2.7 Resistors:
A resistor is a passive two terminal component that implement electrical resistance as
a circuit element. Resistors act to reduce current flow and at the same time act to lower
voltage levels within circuit. In electronic circuit resistors are used to limit current flow

Fig2.9 Resistor
Here we have used 3resistors
R1- 10k,
R2- 2k

2.2.8 Capacitor:
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CHAPTER 1: INTRODUCTION

Fig 2.10 Capacitor

A capacitor is

passive two-terminal electrical

component used

to

store energy electro statically in an electric field. The forms of practical capacitors vary
widely, but all contain at least two electrical conductors separated by a dielectric . The
conductors can be thin films, foils or sintered beads of metal etc. The "none conducting"
dielectric acts to increase the capacitor's charge capacity. A dielectric can be glass, ceramic,
plastic films, air etc.
C1C233pF,
C3 100 pF,
C4C51000F

2.2.9 Battery:

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CHAPTER 1: INTRODUCTION

Fig 2.10Battery
An electric battery is a device consisting of one or more electrochemical cells that
convert stored chemical energy into electrical energy. Each cell contains a positive terminal,
or cathode, and a negative terminal, or anode. Electrolytes allow ions to move between the
electrodes and terminals, which allows current to flow out of the battery to perform work

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CHAPTER 3: AVR ATmega8

Chapter 3

BIKE GEAR INDICATOR

CHAPTER 3: AVR ATmega8

AVR ATMEGA 8

BIKE GEAR INDICATOR

3.1

CHAPTER 3: AVR ATmega8

INTRODUCTION:
The AVR is a modified Harvard architecture 8-bit RISC single chip microcontroller

which was developed by Atmel in 1996. The AVR was one of the first microcontroller
families to use on-chip flash memory for program storage, as opposed to one-time
programmable ROM, EPROM, or EEPROM used by other microcontrollers at the time

3.2 Brief History:

The AVR architecture was conceived by two students at the Norwegian Institute of
Technology (NTH) Alf-Egil Bogen and Vegard Wollan.
The original AVR MCU was developed at a local ASIC house in Trondheim, Norway
called Nordic VLSI at the time, now Nordic Semiconductor, where Bogen and Wollan were
working as students. It was known as a RISC (Micro RISC) and was available as silicon
IP/building block from Nordic VLSI. When the technology was sold to Atmel from Nordic
VLSI,[citation needed] the internal architecture was further developed by Bogen and Wollan
at Atmel Norway, a subsidiary of Atmel. The designers worked closely with compiler writers
at IAR Systems to ensure that the instruction set provided for more efficient compilation of
high-level languages. Atmel says that the name AVR is not an acronym and does not stand for
anything in particular. The creators of the AVR give no definitive answer as to what the term
"AVR" stands for. However, it is commonly accepted that AVR stands for Alf (Egil Bogen)
and Vegard (Wollan's) RISC processor.
Note that the use of "AVR" in this article generally refers to the 8-bit RISC line of
Atmel AVR Microcontrollers.
Among the first of the AVR line was the AT90S8515, which in a 40-pin DIP package
has the same pin out as an 8051 microcontroller, including the external multiplexed address
and data bus. The polarity of the RESET line was opposite (8051's having an active-high
RESET, while the AVR has an active-low RESET), but other than that, the pin out was
identical.

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CHAPTER 3: AVR ATmega8

3.2.1 Categories:
AVR microcontrollers are available in three categories
1. TinyAVR Less memory, small size, suitable only for simple applications
2. MegaAVR These are the most popular ones having good amount memory (up to 256
KB), higher number of inbuilt peripherals and suitable for moderate to complex
applications.
3. XmegaAVR Used commercially for complex applications, which require large
program memory and high speed.

The following table compares the above mentioned AVR series of microcontrollers:

Series Name

Pins

Flash Memory

Special Feature

Tiny AVR

6-32

0.5-8Kb

Small in size

Mega AVR

28-100

4-256Kb

Extended Peripheral

Xmega AVR

44-100

16-384Kb

DMA, Event System

included

Table 3.1 AVR series of microcontrollers

3.3 Pin Out Of ATmega8:

Figure 3.1 Pin diagram of AVR ATmega8

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CHAPTER 3: AVR ATmega8

3.4 Pin Description:

1.

VCC: Digital supply voltage 5V.

2.

GND: Ground.

3.

RESET: A low level on this pin for longer than the minimum pulse length will
generate a reset, even if the clock is not running.

4.

AREF: The analog reference pin for the A/D Converter.

5.

AVCC: The supply voltage pin for the A/D Converter, Port C (3.0).It should be
externally connected to VCC, even if the ADC is not used. If the ADC is used, it should
be connected to VCC through a low-pass filter.

PORT B:
Port B is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each
bit). The Port B output buffers have symmetrical drive characteristics with both high sink and
source capability. As inputs, Port B pins that are externally pulled low will source current if
the pull-up resistors are activated. The Port B pins are tri-stated when a reset condition
becomes active, even if the clock is not running. Depending on the clock selection fuse
settings, PB6 can be used as input to the inverting Oscillator amplifier and input to the
internal clock operating circuit. Depending on the clock selection fuse settings, PB7 can be
used as output from the inverting Oscillator amplifier. If the Internal Calibrated RC Oscillator
is used as chip clock source, PB7.6 is used as TOSC2.1 .Input for the Asynchronous
Timer/Counter2 if the AS2 bit in ASSR is set. The various special features of Port B are
elaborated in table.

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CHAPTER 3: AVR ATmega8

The Port B pins with alternate functions are shown in Table:

PORT PIN

FUNCTIONS

PB7

XTAL2 (Chip Clock Oscillator pin 2)

TOSC2 (Timer Oscillator pin 2)

PB6

XTAL1 (Chip Clock Oscillator pin 1 or External clock input)

TOSC1 (Timer Oscillator pin 1)

PB5

SCK (SPI Bus Master clock Input)

PB4

MISO (SPI Bus Master Input/Slave Output)

PB3

MOSI (SPI Bus Master Output/Slave Input)

OC2 (Timer/Counter2 Output Compare Match Output)

PB2

SS (SPI Bus Master Slave select) OC1B (Timer/Counter1

Output Compare Match B Output)

PB1

OC1A (Timer/Counter1 Output Compare Match A Output)

PB0

ICP1 (Timer/Counter1 Input Capture Pin)

Table 3.2 Description of port B

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CHAPTER 3: AVR ATmega8

PORT C:
Port C (PC5.PC0) Port C is a 7-bit bi-directional I/O port with internal pull-up
resistors (selected for each bit). The Port C output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port C pins that are
externally pulled low will source current if the pull-up resistors are activated. The Port C pins
are tri-stated when a reset condition becomes active, Even if the clock is not running
PC6/RESET: If the RSTDISBL Fuse is programmed, PC6 is used as an I/O pin. Note
that the electrical characteristics of PC6 differ from those of the other pins of Port C. If the
RSTDISBL Fuse is unprogrammed, PC6 is used as a Reset input. A low level on this pin for
longer than the minimum pulse length will generate a Reset, even if the clock is not running.
Shorter pulses are not guaranteed to generate a Reset. The various special features of Port C
are elaborated in Table:
PORT PIN

FUNCTIONS

PC6

RESET (Reset pin)

PC5

ADC5 (ADC Input Channel 5)

SCL (Two-wire Serial Bus Clock Line)

PC4

ADC4 (ADC Input Channel 4)

SDA (Two-wire Serial Bus Data Input/output Line)

PC3

ADC3 (ADC Input Channel 3)

PC2

ADC2 (ADC Input Channel 2)

PC1

ADC1 (ADC Input Channel 1)

PC0

ADC0 (ADC Input Channel 0)

Table 3.3 Description of Port C

PORT D:

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CHAPTER 3: AVR ATmega8

Port D is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each
bit). The Port B output buffers have symmetrical drive characteristics with both high sink and
source capability. As inputs, Port D pins that are externally pulled low will source current if
the pull-up resistors are activated. The Port D pins are tri-stated when a reset condition
becomes active, even if the clock is not running. Depending on the clock selection fuse
settings
The Port D pins with alternate functions are shown in Table:
PORT PIN

FUNCTIONS

PD7

AIN1 (Analog Comparator Negative Input)

PD6

AIN0 (Analog Comparator Positive Input)

PD5

T1 (Timer/Counter 1 External Counter Input)

PD4

XCK (USART External Clock Input/output)

T0 (Timer/Counter 0 External Counter Input)

PD3

INT1 (External Interrupt 1 Input)

PD2

INT0 (External Interrupt 0 Input)

PD1

TXD (USART Output Pin)

PD0

RXD (USART Input Pin)

Table 3.4 Description of Port D

BIKE GEAR INDICATOR

CHAPTER 4: PCB DESIGNING

Chapter 4
PCB DESIGNING

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CHAPTER 4: PCB DESIGNING

4.1 Introduction:
A printed

circuit

board

(PCB) mechanically

supports

and

electrically

connects electronic components using conductive tracks, pads and other features etched from
copper sheets laminated onto a non-conductive substrate. PCBs can be single sided (one
copper layer), double sided (two copper layers) or multi-layer. Conductors on different layers
are connected with plated-through holes called visa. Advanced PCBs may contain
components - capacitors, resistors or active devices - embedded in the substrate.
Printed circuit boards are used in all but the simplest electronic products. Alternatives to
PCBs include wire wrap and point-to-point construction. PCBs require the additional design
effort to lay out the circuit but manufacturing and assembly can be automated. Manufacturing
circuits with PCBs is cheaper and faster than with other wiring methods as components are
mounted and wired with one single part. Furthermore, operator wiring errors are eliminated.

4.2 Lamination:
Multi-layer printed circuit boards have trace layers inside the board. One way to make a
4-layer PCB is to use a two-sided copper-clad laminate, etch the circuitry on both sides, then
laminate to the top and bottom pre-preg and copper foil. Lamination is done by placing the
stack of materials in a press and applying pressure and heat for a period of time. This results
in an inseparable one piece product. It is then drilled, plated, and etched again to get traces on
top and bottom layers. Finally the PCB is covered with solder mask, marking legend, and a
surface finish may be applied. Multi-layer PCBs allow for much higher component density.

4.3 Chemical Etching:

Chemical etching is usually done with ammonium per sulfate or ferric chloride. For
PTH (plated-through holes), additional steps of electrolyses deposition are done after the
holes are drilled, then copper is electroplated to build up the thickness, the boards are
screened, and plated with tin/lead. The tin/lead becomes the resist leaving the bare copper to
be etched away. The simplest method, used for small-scale production and often by

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CHAPTER 4: PCB DESIGNING

hobbyists, is immersion etching, in which the board is submerged in etching solution such as
ferric chloride.

4.4 Drilling:
Holes through a PCB are typically drilled with small-diameter drill bits made of solid
coated tungsten carbide. Coated tungsten carbide is recommended since many board
materials are very abrasive and drilling must be high RPM and high feed to be cost effective.
Drill bits must also remain sharp so as not to mar or tear the traces. Drilling with high-speedsteel is simply not feasible since the drill bits will dull quickly and thus tear the copper and
ruin the boards.

4.5 Eagle Software:

It is one of the software used for designing any circuit which is to be printed and traced
on PCB.

Fig 4.1 Eagle layout

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RESULT

RESULT

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RESULT

As we shift the gear in a bike, hall sensors senses that shift and gives the result on 16*2
LCD panel.
When gear lever shifts from neutral to first gear, result is indicated on LCD as 1.
When gear is shifted from first to second gear, LCD panel displays the result as 2.
This increasing gear level indicates gear shift towards the upper hall sensor which gives
'+1' count to gear indicator.
But when the gear is shifted from upper to lower level, it gives '-1' count to gear
indicator. And in this way the project is working successfully.

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CONCLUSION

CONCLUSION

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CONCLUSION

In the early parts of this project, our vague goals led to a broad scope of ideas, and a
lack of structure. Choosing areas of focus and completing research of prior knowledge in this
area helped us to narrow our design and choose an approach that is feasible.
Many aspects of this project involved learning how particular processes work,
including the PCB layout. Our final design utilized many different aspects of the field of
electronics engineering and design.
The PCB design made our prototype much more secure and aesthetic. The set design
goals were completed, though there is much that can be improved upon.

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REFERENCES

REFERENCES:

1. http://www.circuitstoday.com/avr-atmega8-microcontroller-an-introduction
2. http://www.atmel.com/images/atmel-2486-8-bit-avr-microcontrolleratmega8_l_datasheet.pdf
3. http://en.wikipedia.org/wiki/Microcontroller
4. http://www.electronics-lab.com/projects/automotive/006/index.html