Automatic Speed Control of 1-Ph I.M.

CHAPTER-1 ABSTRACT:
In this automatic speed control of single phase induction motor, speed control is done by successfully comparing actual speed with entered speed. We know now days the scope of electric machines are growing rapidly. Speed control of such an electrical machines to run it at desired value of speed is also essential and microcontroller can done it in very finest way. As we had surveyed speed of electrical machines is a need of todays era with healthy machines and increased efficiency, hence the machine can gives the exact value of desired speed with anti- parallel thyristor based driving circuit. The errorless proximity metal sensor forced to sense the pulse of revolution of motor and give it to microcontroller and finally is getting displayed on the liquid crystal display in revolution per second i.e. in RPS.

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CHAPTER-2 INTRODUCTION:
The speed of induction motor can be reduced by decreasing stator voltage by an amount which is sufficient for the speed control of some drives. While torque is proportional to voltage squared, current is proportional to voltage therefore, as voltage is reduced to reduce speed, for same current motor develops lower torque. Consequently, method is suitable for application where torque demand reduces with speed, which points towards its suitability for fan and pump drives. Variable voltage for speed control is obtained using ac voltage controllers. Industrial fans and pumps are usually driven by induction motors. Thyristors are commonly used for controlling the voltage to control the speed of induction motor. Speed control is obtained by varying conduction period of thyristors. For low power rating machines, anti-paralleled thyristor pair is used. Speed of the motor can be varied more or less uniformly in the range of 80% to 30% of synchronous speed of the motor by varying the voltage between 100% to 30%. The stator voltage is controlled in these speed control systems by means of a power electronic controller. Here two thyristors in anti parallel are connected between the line and motor in a phase. Normally thyristors in phase control mode are used. It is also possible to fire the thyristors for only a portion of the cycle, thus utilizing conduction angle manipulation. This is useful in motor control. The conduction of thyristor pair is controlled by changing firing angle of thyristors through microcontroller.

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CHAPTER-3 FUNCTIONAL SPECIFICATION:

3.1 Supply specification:
Type of Supply: Single Phase Voltage: 230V Frequency: 50Hz

3.2 Electronic circuit specification:

Type of Supply: DC Voltage: +5V Regulated, Ground.

3.3 Motor Specification:

Voltage: 240v Current: 0.3A Hz: 50 RPM: 1360 WATTS: 9 HP: 1/83 INSULATION CLASS: A RATING: CONT

3.4 Driver circuit specification:

UNISON SSR Dc to ac solid state relay (back to back SCR) 801 RDA 48 25 00 (801 model single phase ac load) Input: 4-32Vdc, 4-16mA Output: 24-480Vac, 25A

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(Back to back SCR-silicon control rectifier with heat sink & 35mm din rail mounting.)

CHAPTER-4 BLOCK DIAGRAM & WORKING:

Fig.(A) Block diagram

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T1

G1

G2
230V 50 Hz

T2

1-Ph I.M.

Fig.(B) Working of driver circuit.

It is based upon the silicon controlled rectifier or thyristor. By pulsing a thyristor, it switches from off to on until the current stops flowing through it, which occurs every half cycle in an AC supply. By controlling electronically the thyristor turn on point, it is possible to regulate the energy passing through it. By starting with a large delay angle and gradually reducing it, the motor terminal voltage is increased from a low value to full value, giving a smooth, step less start. In short, by carefully controlling the motor voltage at starting with the help of thyristor, the speed can be controlled. As shown in above fig the connection of anti-parallel thyristor in series with induction motor having 230V, 50 Hz ac supply. In positive half cycle of ac supply the thyristor T1 conducts, during that state thyristor T2 is in OFF condition and according to firing angle of thyristor T1 the voltage appears across induction motor. As same, in the negative half cycle of ac supply, the thyristor T2 conducts, during that state thyristor T1 is in OFF condition and according to firing angle of thyristor T2 the voltage appears across induction motor. According to the variation of firing angle of both thyristor, the

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respective voltage appears across induction motor. Because of this voltage stator flux will gets changed, resulting in change in speed of induction motor.

CHAPTER-5 HARDWARE DETAILS:

5.1 POWER SUPPLY:
Circuit Diagram:

The dimmer is to be a self-contained unit and thus requires a power supply to provide low voltage DC for its electronics from the AC power line. The microcontroller need +5V DC, These specifications dictate the use of a low-cost, ubiquitous linear regulator National Semiconductor LM7805. The LM7805 requires an input voltage of at least 7.5V in order to guarantee regulation, so the unregulated power supply should supply at least this voltage under worst-case current consumption, assumed to be about 200mA.

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Because a full-wave rectifier will be used for efficiency (diodes D1-D2), we can assume that about 1.4V will be lost across the bridge (0.7V per conducting diode). We therefore need a transformer was selected as T1, which is of rating 9-0-9 secondary at 500 mA Positive Voltage Regulator (IC 7805):

Voltage regulator is commonly weal for on card regulators and laboratory type. Power supplies, at most all power supplies we some type of IC voltage regulator. Because voltage regulators are simple to use, reliable, low in cost and above all available in variety of voltage and current rating. We use in our project fixed voltage regulator. The 7800 series are fixed voltage regulator IC. Although these device do not require external components such components can be used to obtain adjustable voltage and currents. This IC s also has internal thermal overload protection and internal short circuit current limiting. Following are the connection diagrams of IC 7805 which provide +5. The capacitors Cin and Cout are used to nullify inductance due to input wires and to improve the transient response.

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5.2 ZERO CROSSING DETECTOR:

Circuit Diagram:

Input output Waveform:

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In order for the thyristor pair to determine at which point on the AC cycle to turn on invidiously, it needs a reference for the AC zero crossing. Zero crossing detector is used to convert sine wave or other signal into square-wave, the output should be low if the input is positive and high if the input if negative. I contract to sine wave oscillators, square wave outputs are generated when the op-amp is forced to operate in the saturated region. That is the output of op-amp is forced to swing repetitively between positive saturation +Vsat ( +Vcc) and negative saturation Vsat ( -Vcc), resulting in square wave output. LM339 Pinout:

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As shown in figure above LM339 consists of four op-amps inside it. From which one of the op-amp is used for zero crossing detection.

5.3 MICROCONTROLLER AT89S52:

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5.3.1 MICROCONTROLLER AT 89S52 FEATURES: Compatible with MCS 51 products 8k bytes of in system Re-programmable Flash Memory Fully static operation : 0 Hz to 24 MHz 256 x 8 bit internal RAM 32 programmable I/O Lines Three 16 bit Timer or Counters 8 Interrupt sources Programmable serial channel Low power Idle & power down modes

5.3.2 MICROCONTROLLER AT 89S52 DISCRIPTION:

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The Microcontroller IC 89S52 has 256x8 bit internal RAM which is most important feature for this application. Here eight to ten readings can be recorded in RAM after each half an hour to achieve data logging. The Timer/Counter application of 89S52 is used to count the pulses from proximity sensor. The interrupt pin INTR0 is used to switch into different setting modes The serial channel is used to get interface with pc for data logger application. The AT89C52 provides the following standard features: 8Kbytes of Flash, 256 bytes of RAM, 32 I/O lines, three 16-bittimer/counters, a six-vector two-level interrupt architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the AT89C52 is designed with static logic for operation down to zero frequency and supports two software selectable power saving modes. The Idle Mode stops the CPU while allowing the RAM, timer/counters, serial port, and interrupt system to continue functioning. The Power down Mode saves the RAM contents but freezes the oscillator, disabling all other chip functions until the next hardware reset.

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5.3.3 AT 89S52 PINOUT:

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Port 0 Port 0 is an 8-bit open drain bidirectional I/O port. As an output port, each pin can sink eight TTL inputs. When 1s are written to port 0 pins, the pins can be used as high impedance inputs. Port 0 can also be configured to be the multiplexed low order address/data bus during accesses to external program and data memory. In this mode, P0 has internal pull-ups. Here port 0 is used as Data lines to LCD. Port 1 Port 1 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 1 output buffers can sink/source four TTL inputs. When 1s are written to Port 1 pins, they are pulled high by the internal pull-ups and can be used as inputs. In addition, P1.0 and P1.1 can be configured to be the timer/counter 2 external count input (P1.0/T2) and the timer/counter 2 trigger input (P1.1/T2EX). Here Port 1 is used Data lines to the ADC and simultaneously by using Buffer they are used for addressing of mode selection switches. Port 2 Port 2 is an 8-bit bidirectional I/O port with internal pullups. The Port 2 output buffers can sink/source four TTL inputs. When 1s are written to Port 2 pins, they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 2 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. Here Port 2 is used for different functions as, P2.0-2 for channel selection of ADC. P2.3 for accepting Start of Conversion signal from ADC. Port 3 Port 3 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 3 output buffers can sink/source four TTL inputs. When 1s are written to Port 3 pins, they are pulled high by the internal pull-ups and can be used as inputs. Port 3 also serves the functions of various special features of the AT89S52, as shown in following table. Here Port 3 pins are used for many different functions.

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Timer Control (TCON) Special Function Register:

TF1

TR1

TF0

TR0

IE1

IT1

IE0

IT0

Symbol TF1 TR1 TF0 TR0 IE1 IT1 IE0 IT0

Position TCON.0 TCON.1 TCON.2 TCON.3 TCON.4 TCON.5 TCON.6 TCON.7

Function Timer 1 over flow flag. Timer 1 run control bit. Timer 0 over flow flag. Timer 0 run control bit. External Interrupt 1 Edge flag. External Interrupt 1 signal type control bit External Interrupt 0 Edge flag. External Interrupt 0 signal type control bit.

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Timer Mode Control (TMOD) Special Function Register:

Gate

C/Tbar

M1

M0

Gate

C/Tbar

M1

M0

Symbol Gate C/Tbar M1 M0 D7/3

Position

Function OR gate enable bit which controls RUN/STOP Of Timer 1/0

D6/2 D5/1 D4/0

Set to 1 by program to make timer 1/0 act as timer / Counter. Timer/ Counter operating mode select bit 1. Timer/ Counter operating mode select bit 0.

Mode selection: M1 0 M0 0 1 0 1 1 Mode 0 1 0 3 2

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Serial Port Control (SCON) Special Function Register:

SM0

SM1

SM2

REN

TB8

RB8

TI

RI

Symbol SM0 SM1 SM2 REN TB8 RB8 TI RI

Position SCON.0 SCON.1 SCON.2 SCON.3 SCON.4 SCON.5 SCON.6 SCON.7

Function Serial port mode bit 0. Set / cleared to select Mode. Serial port mode bit 1. Set / cleared to select Mode. Multiprocessor communications bit Receive enable bit Transmitted bit 8 Received bit 8 Transmit Interrupt flag Receive Interrupt flag

Mode selection: SM0 0 0 1 1 SM1 0 1 0 1 SM2 0 1 2 3 Description Shift register, baud = f/12 8 bit UART, baud = variable 9 bit UART, baud = f/32 or f/64 9 bit UART, baud = variable

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INTERRUPTS: The AT89C52 has a total of six interrupt vectors: two external interrupts (INT0 and INT1), three timer interrupts (Timers 0, 1, and 2), and the serial port interrupt. Each of these interrupt sources can be individually enabled or disabled by setting or clearing a bit in Special Function Register IE. IE also contains a global disable bit, EA, which disables all interrupts at once. In the AT89S52, bit position IE.5 is also unimplemented. User software should not write 1s to these bit positions, since they may be used in future AT89 products. Timer 2 interrupt is generated by the logical OR of bits TF2 and EXF2 in register T2CON. Neither of these flags is cleared by hardware when the service routine is vectored to. In fact, the service routine may have to determine whether it was TF2 or EXF2 that generated the interrupt, and that bit will have to be cleared in software. The Timer 0 and Timer 1 flags, TF0 and TF1, are set at S5P2 of the cycle in which the timers overflow. The values are then polled by the circuitry in the next cycle. However, the Timer 2 flag, TF2, is set at S2P2 and is polled in the same cycle in which the timer overflows.

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Interrupt Enable (IE) Register:

Symbol EA

Position IE.7

Function Disables all interrupts. If EA = 0, no interrupt is

acknowledged. If EA = 1, each interrupt source is individually enabled or disabled by setting or clearing its enable bit. ET2 ES ET1 EX1 ET0 EX0 IE.6 IE.5 IE.4 IE.3 IE.2 IE.1 IE.0 Reserved. Timer 2 interrupt enable bit. Serial Port interrupt enable bit. Timer 1 interrupt enable bit. External interrupt 1 enable bit. Timer 0 interrupt enable bit. External interrupt 0 enable bit.

5.3.4 BUFFER IC 74LS245:

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These octal bus transceivers are designed for asynchronous two-way communication between data buses. The device allows data transmission from the A bus to B bus or from the B bus to A bus depending upon the logic level at the direction control (DIR) input. The enable input can be used to disable the devices so that the buses are effectively isolated. 74LS245 Pinout:

Features: Bi- directional bus transceiver in a high density 20 pin package. Tri-state outputs drive bus lines directly. PNP inputs reduce DC loading on bus lines. Hysteresis at Bus inputs improves Noise margins. Typical propagation delay times port to port 8ns. Typical enable or disable times 17ms.

5.4 16X2 LCD:

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LCD indicates different mode settings & set point adjustment. Also 16 char are divided to indicate speed output. The LCD Display used here is 16 character by 2 line display. The 16 characters in both lines are equally divided to indicate commands and speed. In sub routines Enter Speed and Current Speed message, set Speed value is indicated on screen. In our project LCD is interfaced with the port-0 (D0-D7) i.e. from pin number 32 to pin number 39. In other words the data-bus D0-D7 is connected to port-0 of IC 89s52. Pin RS is directly connected to Pin11 of controller and one more another important pin EN (LCD enable) is directly connected to pin 14 of the controller. On the other hand pin R/W of LCD is connected to ground. The LCD interfacing is done here for indicating various display messages for the user. The interfacing is given in detail which is as follows:In this equipment the LCD which is used is 16X2 type. i.e. 16 characters per rows and two rows. The function of LCD is to display the status of events performed by the respective circuit or to display those resulting parameters which have to be displayed on the screen as per user requirement.

5.4.1 Basics of LCD:

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LCD has 8 Bit data (D0-D7). Basically LCD requires three control signals which are1. R/W: - Read/Write signal when low it is configuring as write function. 2. RS : - The display contains two internal byte-wide registers, one for commands (RS=0) and the second for characters to be displayed (RS=1).
1.

Command: Commands are such as Character size, rows and columns, cursor movement, blink

cursor etc. Basically LCD can be configured in the two modes which are nothing but Slave mode and Handshake mode. In the slave mode a command is transferred to LCD and wait for some delay for the specific time which is normally 6msec. On the other hand i.e. in the handshake mode the D7 bit is used. After the completion of the task the D7 bit is set high by the display.

5.4.2 16X2 LCD INTERFACING:

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Circuit Diagram:

5.5 4X4 KEYPAD:

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The 4x4 Keypad has 16 keys and requires a single PORT or 8 I/O lines. Port 3 has been designed to handle keypad, LCD Data Bus D7-D0 is connected to PORT 1, while (Enable) EN is connected to P2.0 (Register Select Command or Data Register) RS is connected to P2.1 (Read/Write) RW is connected to P2.2. Working: To check for the keystroke, a polling method has been used.

PORT 1.0 PORT 1.1 PORT 1.2 PORT 1.3

Key 1 Key 5 Key 9 Key 13

Key 2 Key 6 Key 10 Key 14

Key 3 Key 7 Key 11 Key 15

Key 4 Key 8 Key 12 Key 16

PORT 1.4 PORT 1.5 PORT 1.6 PORT 1.7 The connections are similar as shown over here. Now consider this, if I select the first column only, it has 4 keys, 1, 5,9,13. If a change of value (i.e. Binary 1 or 0) is made any one of these keys, it can be decoded and suitable message is displayed on the LCD. This is exactly what happens. Initially all the I/O lines are pulled high, then during Key Scan, every column linked is held low for a little time. If during that time a Key is

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pressed in that column a row I/O lines is also held low, thus the keystroke can be captured. The answer is simple, the microcontroller runs quite fast, even a convention 89s52 in which the internal frequency= external frequency clock/12 can achieve 2 MIPS at 24MHz. That is 2 Million instructions Per Second. This method is not foolproof, it has a drawback, while the Key Scan, It cannot perform other cumbersome operations which may take time and a Key Stroke could be missed. The program will work very well for small operations like activating a small relay or LED when a Key is pressed, but for people who want their systems to be near to perfect they may utilize other method.

5.5.1 4X4 KEYPAD SCHEMATIC:

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Circuit Diagram:

5.6 SENSOR:

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Proximity Sensor:

Features: Stainless steel face and barrel for high strength. Available with abrasion resistant, fire retardant ToughLink cable. Electrical protections against short circuits, overload, transient noise, false pulses and reverse polarity (DC models) to help reduce downtime and maintenance costs Extended range models available.

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The proximity sensor used in our project is of inductive type which senses the proximity up to 5mm distance. When the metal strip mounted on the fan belt comes ahead of sensor a high to low pulse gets generated approximately of 3v magnitude and is counted by the counter. The sensor is engineered for enhanced toughness and flexibility, the latest flat pack offers one of the longest sensing distances in the industry. This increased sensing distance reduces target-to-sensor collisions by allowing the sensor to be mounted at a safer distance from the target area. The durable one-piece housing provides superior resistance to the elements. Superior LED visibility and complementary outputs on standard models add even more appeal to this feature-rich inductive proximity sensor.

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5.7 DRIVER CIRCUIT:

5.7.1 SSR (Solid State Relay):

Specifications:
UNISON SSR DC TO AC SOLID STATE RELAY (BACK TO BACK SCR) 801 RDA 48 25 00 (801 MODEL Single Phase AC load) INPUT: 4-32VDC, 4-16mA OUTPUT: 24-480VAC, 25Amp (BACK TO BACK SCR-silicon

control rectifier) With Heat Sink & 35mm Din Rail Mounting.

5.7.2 Supply Voltage Vs SSR Output:

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5.7.3 Advantages of SSR: No contact arcing, high surge capability High resistance to shock and vibration High resistance to aggressive chemicals and dust No electromechanical noise Logic compatibility Fast switching Low coupling capacitance Long Life and high reliability more than 1010 cycle operations Increases system temperature accuracy Unique Input & Output LED indication gives heater failure status & increases surge current / voltage capacity. 5.7.4 Limitations of SSR:

Contact voltage drop Do not have potential free contacts Do not have multiple contacts in one module Having Leakage currents Heat sink is must for heat dissipation for current more than 3Amp Possibility of false switching due to voltage transients.

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5.8 PCB DESIGN: 5.8.1 PCB Layout:

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CHAPTER-6

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SOFTWARE DETAILS:
6.1 PRILIMANARY FLOW CHART:

CHAPTER-7

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ADVANTAGES:

Smooth & step less speed control over wide range. User friendly. Efficiency is high due to Small power loss in power electronic devices i.e. driver circuitry. Fully automatic speed control. Continuous speed indication. Compact size. Accuracy is high. Simultaneous speed control of number of motors can be achieved. E.g.:- Paper Industries, Textile Industries.

CHAPTER-8

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DISADVANTAGES:
Rotor heating is more due to high rotor losses. Sensitive to voltage fluctuations. For lower speed efficiency lowers. Harmonics are generated due to change in supply voltage by power electronic devices. Low torque.

CHAPTER-9

COSTING OF MATERIAL:
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Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Components Microcontroller (AT89S52) LCD Display (16X2) Keypad (4x4) PCB(including general purpose) Induction motor Proximity Sensor Solid State Relay Regulator (IC 7805) Buffer ( IC 74LS245) Crystal (11.0859MHz) Transistors Capacitors 1.1000f 4 2.10 f 1 3.33pf 2 Registers Resister Array LED Diodes(IN 4007) IC LM339 Transformer(230V/9-0-9V) Zener diode(IN 914) Variable Resistance

Quantity 1 1 1 4 1 1 1 2 1 1 2 7

Cost 85.00 450.00 180.00 1000.00 900.00 750.00 850.00 50.00 15.00 25.00 30.00 130.00

13. 14. 15. 16. 17. 18. 19. 20.

14 1 1 8 1 2 1 1

20.00 05.00 05.00 40.00 40.00 85.00 20.00 10.00 4690.00

Total cost =

CHAPTER-10

APPLICATIONS:

Industrial fan speed control.

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For industrial pump drives Transformer coil winding machine. To wound bobbin of fabrics in textile industry. For intermittent duty loads.

CHAPTER-11

FUTURE SCOPE:

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In this automatic speed control of single phase induction motor, speed control is done successfully by comparing actual speed with entered speed. The protective features can be added later as follows Microcontroller can directly provide over current protection to the drive

motor. Simply by adding the preset value of current in the programming the motor can be protected from the abnormal conditions.

For the speed control, stator voltage control method is used. In this method

when voltage decreases below certain level rotor losses increases resulting to rotor heating. Therefore advanced temperature sensors can be used to detect rotor heating which can further be operated the better cooling system for the motor.

Simultaneous speed control of number of motors can be achieved by

providing number of channels from the microcontroller.

CHAPTER-12

CONCLUSION:

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Finally we come to the result that, the speed of Induction Motor is controlled over wide range with the help of stator voltage control technique. This project is applicable where the speed required at any specific value. The theory of stator voltage control method for speed control of induction motor gives the maximum efficiency will be achieved in specific region of speed i.e. 30% to 80% of synchronous speed for the voltage 30% to 100.

CHAPTER-13

REFERENCES:

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1) 2) 3) 4) 5)

Kenneth J. Ayala., 8051 Microcontroller, Mohammed Ali Mazadi., 8051 Microcontroller, Vaibhav Tarate., Electronic System Design Ramakant Gaikwad., Linear Integrated Circuits National Semiconductor Manual.

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