CAR HEAD LIGHTS DIMMER

Submitted in the partial fulfillment of the requirement for the award

DIPLOMA

IN MECHANICAL ENGINEERING (AUTOMOBILE )

SUBMITTED BY:

1. L. MANIKANDAN 2. R. PRABAKARAN 3. D. RAJESH

4. C. RAJI 5. K. VENUGOPAL 6. R. SRINIVASAN

Under guidance of N.RAMU, M.E. MARCH 2008 DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY). A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE CHENNAI 602103

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE CHENNAI- BANGALORE ROAD SEMBARAMBAKKAM CHENNAI 602103

BONAFIDE CERTIFICATE
This is to certify that this Project work on
CAR HEAD LIGHTS DIMMER

submitted by . Reg. No. in partial fulfillment for the award of DIPLOMA IN MECHANICAL ENGINEERING (AUTOMOBILE) This is the bonafide record of work carried out by him under our supervision during the year 2008 Submitted for the Viva-voce exam held on ..

H.O.D

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the Principal Mr. R.J. KUMAR, M.E.F.I.E, M.I.S.T.E for encouragement and valuable advice.

we thank our Esquired Head of Department Mr. S.N.SUNDAR, M.E. for presenting his felications on us. We are grateful on our Entourages Mr. N.RAMU, M..E. For guiding in various aspects of the project making it a grand success. We also owe our sincere thanks to all staff members of the Mechanical Department and Foundry Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS
CHAPTER NO. 1 2 3 4 1 TITLE SYNOPSIS CONSTRUCTION WORKING PRINCIPLE MECHANICAL ASSEMBLY DIAGRAM CIRCUIT DETAILS (BLOCK DIAGRAM) (a) Mother Board (b) Display Board (c) Interface Circuit 5 to 12V (d) Key Board interface (e) Power supply unit 5V and 12V
(f) LDR Sensor unit

2 3 4 5

ELECTRICAL CIRCUIT DIAGRAM COST ESTIMATION CONCLUSION BIBLIOGRAPHY

SYNOPSIS

AUTOMATIC CONTROL OF CAR HEAD LIGHTS DIMMER SYNOPSIS

The main aim of this project is to gain the practical knowledge in the field of automation using microcontroller.

In our project AUTOMATIC CONTROL OF CAR HEAD LIGHTS DIMMER works on the principle of fuzzy logic .Fuzzy logic will give very smooth variation of light intensity from natural to artificial lighting.

Here the head lights is switched ON/ OFF/ dim / bright depending on the lights outside the car (day/night).A light sensor is fixed at any part of the bonnet, this sensor produces voltage depending on the light intensity.

This voltage is sent to a processor which manipulates the voltage and control the head light during day time.

CONSTRUCTION

CONSTRUCTION
The construction of the car head light dimmer is shown in the fig.

CAR HEAD LIGHT DIMMER

LDR (SENSOR) LIGHTSOURCE HEADLIGHT

NOVOPAN PLYWOOD

In this project consist of 1. 2. 3. 4. 5. Head light (Bonnet) Assembly with LDR Source of light Power supply Micro controller switch Inter face circuit

WORKING PRINCIPLE

WORKING PRINCIPLE

In this project, a LDR is fixed nearer to the head light and it is having the resistance value of 10 kiloohms under normal conditions.when the light intensity is increased, the resistance value automatically decreases and the corresponding signal voltage to the microcontroller changed. Here one PIC 16 F 870 (28 PIN IC ) microcontroller is used for controlling the head light.

This LDR sensor is connected to the microcontroller , and when the voltage signal from the LDR changes,the microcontroller correspondingly gives output to the head light bulb through the interface card.

The interface card is used to connect the 5VDC signal from the microcontroller to the 12VDC headlight bulbs.

Fuzzy logic means when the input varies between 0 to 1 logic, the system should gives the variable output.

HARD WARE CIRCUIT REQUIREMENTS

The hardware circuit requirements details consists of 1. Micro controller system 2. Power supply (230V A.C. to 12 V and 5V DC) 3. LCD Display 4. 5 TO 12 V Drive Card 5. LDR SENSOR CIRCUIT MICRO CONTROLLER SYSTEM: This system monitors the engine condition by using PIC 16F870 (28 pin IC Package) micro controller. The pin details of micro controller are shown in figure.

The circuit diagram for this micro controller board is shown below,

MOTHER BOARD CIRCUIT DETAILS

the reset switch is connected to PORTA (i.e)pin no 1, The BULBS are iconnected to PORT B, 7,6 and the LCD is connected to PORT C, The power supply is connected to Pin 19 & 20.The sensor is connected to PORTA ,1.

Keypad interface; Here seven soft microswitches are soldered in the main board and their connections are shown below.

P O R T B (K E Y P A D )IN P U T & O U T P U T C IR C U IT

b) Display unit circuit:

Here two row &16 charactors LCD display is used to show the linear dimension of the specimen. The LCD is mounted on the separate pcb board and it is screwed on the novopan board. The LCD display is interface with the microcontroller through PORTC 0-7.& PORTB 0,1.The LCD Pin connections are shown below.

LCD WIRING DIAGRAM

POWER SUPPLY UNIT

INTRODUCTION: All the electronic components starting from diode to Intel ICs only work with a DC supply ranging from +5V to +12V. We are utilizing for the same, the cheapest and commonly available energy source of 230V-50Hz and stepping down, rectifying, filtering and regulating the voltage. STEP DOWN TRANSFORMER: When AC is applied to the primary winding of the power transformer, it can either be stepped down or stepped up depending on the value of DC needed. In our circuit the transformer of 230V/15-0-15V is used to perform the step down operation where a 230V AC appears as 15V AC across the secondary winding. Apart from stepping down voltages, it gives isolation between the power source and power supply circuitries. RECTIFIER UNIT: In the power supply unit, rectification is normally achieved using a solid state diode. Diode has the property that will let the electron flow easily in one direction at proper biasing condition. As AC is applied to the diode, electrons only flow when the anode and cathode is negative. Reversing the polarity of voltage will not permit electron flow. A commonly used circuit for supplying large amounts of DCpower is the bridge rectifier. A bridge

rectifier of four diodes (4 x IN4007) are used to achieve full wave rectification. Two diodes will conduct during the negative cycle and the other two will conduct during the positive half cycle, and only one diode conducts. At the same time one of the other two diodes conducts for the negative voltage that is applied from the bottom winding due to the forward bias for that diode. In this circuit due to positive half cycle D1 & D2 will conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of 100Hz. Since each alteration produces a resulting output pulse, frequency = 2 x 50 Hz. The output obtained is not a pure DC and therefore filtration has to be done. The DC voltage appearing across the output terminals of the bridge rectifier will be somewhat less than 90% of the applied rms value. Normally one alteration of the input voltage will reverse the polarities. Opposite ends of the transformer will therefore always be 180 degree out of phase with each other. For a positive cycle, two diodes are connected to the positive voltage at the top winding.

FILTERING CIRCUIT: Filter circuits which is usually capacitor acting as a surge arrester always follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a bypassing capacitor, is used not only to short the ripple with frequency of 120Hz to ground but also to leave the frequency of the DC to appear at the output. A load resistor R1 is connected so that a reference to the ground is maintained. C1, R1 is for bypassing ripples. C2, R2 is used as a low pass filter, i.e. it passes only low frequency signals and bypasses high frequency signals. The load resistor should be 1% to 2.5% of the load. 1000f/25V : for the reduction of ripples from the pulsating 10f/25V 0.1f : for maintaining the stability of the voltage at the load side. : for bypassing the high frequency disturbances

BLOCK DIAGRAM FOR POWER SUPPLY

STEP DOWN

BRIDGE

POSITIVE

TRANSFORMER

RECTIFIER

CHARGE CAPACITOR

5V REGULATOR

12V REGULATOR

MOTHER BOARD

DISPLAY BOARD

RELAY

VOLTAGE REGULATOR: The voltage regulators play an important role in any power supply unit. The primary purpose of a regulator is to aid the rectifier and filter circuit in providing a constant DC voltage to the device. Power supplies without regulators have an inherent problem of changing DC voltage values due to variations in the load or due to fluctuations in the AC linear voltage. With a regulator connected to the DC output, the voltage can be maintained within a close tolerant region of the desired output. IC7812 and 7912 is used in this project for providing +12V and 12V DC supply.
SPECIFICATION:

Resistors R1 and R2 maintain line load regulation. At the secondary side of the transformer, applied vlltage = 15V Conducting drop across the diodes = 2 * 0.6 = 1.2V Without capacitor: Vavg = (15-1.2)V = 13.8c pulsating DC Frequency = 100Hz With capacitor: V = Vavg * 1.414 (form factor) = 19.51V Frequency = 0 Hz with 7812 voltage regulator:

V0 = +12V with 7912 voltage regulator: V0 = -12V

5 to 12V interface circuit:

Here we have to drive the 12V DC load. The 5V signal from the PIC 16F870 micro-controller is fed into the input of interface circuit. TIP 120 Darlington transistor is used here for high speed switching purpose and the Diode IN 4007 is for the safety of TIP 120 transistor during the collapsing of magnetic field from the 12 DC ALARM coil. This interface circuit is shown in fig.

5V TO 12V INTERFACE CIRCUIT

INTRODUCTION TO MICROCONTROLLER

INTRODUCTION TO MICROCONTROLLER PIC WITH RS-232

INTRODUCTION: The PIC Microcontrollers are supported with a full range of Hardware and software development tools. The used PIC16F870 device comes in 28 pin package. To communicate with the PIC we are using RS-232 standard port of computer. In personal computer, data transfer takes place serially. RS-232 standard is used for serial communication. PIC Microcontroller is linked to PC through the RS-232 port. The PC displays the menu for selecting the calibrating equipment and all the calibration results graphically and in tabular form. The user can access the calibration reports, comparison graphs etc at any time using the menu offered in the PC. PIC MICROCONTROLLER: The PIC Microcontrollers are supported with a full range of hardware and software development tools. The used PIC16F870 device comes in 28 pin package. To communicate with the PIC we are using RS-232 port of the computer. So we have to initialize the port before using it. To initialize and to communicate with the PIC, the file COM.C defines and uses several functions.

MICROCONTROLLER CORE FEATURES: High-performance RISC CPU Only 35 single word instructions to learn All single cycle instructions except for program branches which are two cycles Operating speed: DC-20 MHz clock input DC 200 ns instruction cycle 4K x 14 words of Program Memory, 256 x 8 bytes of Data Memory (RAM) Interruput capability (upto 14 Internal / External interrupt sources) Eight level deep hardware stack Direct, indirect, and relative addressing modes Power-on Reset (POR) Power-up Timer (PWRT) and Oscillator Start-up Timer (OST) Watchdog timer (WDT) with its own on-chip RC oscillator for reliable operation Programmable code-protection Power saving SLEEP mode Selectable oscillator options

 Low-power, high-speed CMOS EPROM technology Fully static design In-circuit Serial Programming (ISC) Wide operating voltage range: 2.5V to 5.5V High Sink / Source current 25/25 mA Commercial and Industrial temperature ranges Low power consumption <2 mA at 5V, 4 MHz 22.5 mA typical at 3V, 32 KHz <1 mA typical standby current

PERIPHERAL FEATURES: Timer 0: 8-bit timer / counter with 8-bit prescaler Timer 1: 16 bit timer / counter with prescaler, can be incremented during sleep via external crystal/clock Timer 2: 8 bit timer / counter with 8 bit period register, prescaler and postscaler Two capture, compare, PWM modules Caputure is 16 bit, max. resolution is 12.5 ns Compare is 16 bit, max. resolution is 200 ns, PWM max. resolution is 10 bit 12 bit multi channel Analog-to Digital converter On-chip absolute band gap voltage reference generator Synchronous Serial Port (SSP) with SPI (Master Mode) and I 2 C Universal Synchronous Asynchronous Receiver Transmitter, supports high / low speeds and 9 bit address mode (USART/SCI) Parallel Slave Port (PSP) 8 bits wide, with external RD, WR and CS controls

 Programmable Brown out detection circuitry for Brownout Reset (BOR) Programmable Low-voltage detection circuitry

FEATURES OF THE CAR HEAD LIGHT DIMMER

FEATURES OF THE CSR HEAD LIGHT DIMMER

1. The cost of the unit is less. 2. It is simple in operation 3. It can be fitted any automobile vehicle. 4. The current consumption is very less. 5. Repair and maintenance is easy.

ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

PORT B (KEYPAD)INPUT & OUTPUT CIRCUIT

MOTHER BOARD CIRCUIT DETAILS

5V TO 12V INTERFACE CIRCUIT

LCD WIRING DIAGRAM

L D R S E N S O R U N IT

COST ESTIMATION

COST ESTIMATION

1. Main circuit board 2. Power supply 12VDC

-------------- 2100.00 -----------220.00 80.00 350.00 650.00

3. 12V DC BULB X 4 NOS--------- ----------4. BONNET With stand ----------------------

5. Inter face circuit---------------------------------6. Novopan board

----------------- 100.00 900.00 200.00 100.00 700.00 ----------------

7. LCD DISPLAY--------------------------------8. Transportation Charges-------------------------9. Miscellanies charges ----------------------------10.Report ---------------------------------------------

5400.00 -------------------

CONCLUSION

CONCLUSION

We have successfully completed the project work on AUTOMATIC CONTROL OF CAR HEAD LIGHTS DIMMER at our institute.

By doing this project work, we understood the working principle and uses of various sensors, switches, relays and motors. As more and more industries are automating their manufacturing process, it will be of no doubt that micro controller will be an integral part of any process in industry in the near future and we have utilized the micro controller for the completion of this project.

Once again we express our sincere thanks to our staff members.

BIBILOGRAPHY

BIBILOGRAPHY

1.Welding technology by ROBERT 1. Production technology by Hajra Choudry 3.Automobile technology by Prasad