2011 PERTANDINGAN KEMAHIRAN MALAYSIA

(ELEKTRONIK)

SOALAN
PERINGKAT AKHIR
NAMA: ______________________________________ NO. KP: ______________________________________

JABATAN PEMBANGUNAN KEMAHIRAN KEMENTERIAN SUMBER MANUSIA

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Project: Hardware Design

Hardware Circuit Design: Time limit is 3 hours. Design of Printed Circuit Board: Time limit is 2 hours. Build and Test Designed Prototype: Time limit is 2 hours. INTRODUCTION This project is to test the competitors skill in hardware and printed circuit board design for a stepper motor controller. A simple block diagram of stepper motor system is shown in Fig.1. A unipolar stepper motor with 6 control wires is used. The competitor will design the controller, which can control the rotating direction and stepping rate of the motor.

Power Supply

Direction Controller Stepping Rate

Stepper Motor

Figure 1 Block diagram of stepper motor control system Fig. 2 illustrates more detail diagram of the designed system. The system consists of 2 major parts, i.e. 1) a 6-wire unipolar stepper motor and 2) a controller. In the controller, the control signal generator produces a set of sequential signals (SAA, SAB, SBA and SBB) that is suitable to drive the motor. To enhance controller performance, however, the control signals are amplified by the driver circuit. The driver output signals are then connected to the stepper motor. The rotating command (Clockwise/Counter Clockwise) and stepping rate (Step/Second) of motor can be controlled via switches SW1, SW2 and SW3, respectively. Basically, the stepping rate of the motor can be controlled by adjusting the frequency of supplied clock signal. The control signal generator can be received its clock signal from 2 different sources, which are either external clock (EXCLK) or internal clock (INCLK). The signal from standard function generator can be used as EXCLK. To make the controller as standalone unit, the INCLK is employed. The INCLK is square wave generator, whose output frequency can be adjusted. The 7805 circuit is employed to generate 5V for onboard both the control signal generator and INCLK circuit.

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+12V GND 7805 CIRCUIT +5V +12V L1 SW1 SW2 COMMAND SBA CONTROL SIGNAL GENERATOR SW3 SPEED SBB L4 INCLK DRIVER GND CONTROLLER
Figure 2 Detail of stepper motor control system.

SAA

L2 L3 SAB

EXCLK From Function Generator

6-WIRE UNIPOLAR STEPPER MOTOR

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Pertandingan Kemahiran Malaysia (PKM)

INSTRUCTIONS TO COMPETITORS

1. Hardware Circuit Design (3 Hrs) The competitors will design the following 3 circuits and implement them on a proto-board by selecting components from the material list. 1.1 7805 circuit
This circuit is employed to step down the 12V supply to 5V used for digital components.

1.2 Design Control Signal Generator

This sequential digital circuit consists of 2 inputs, i.e. COMMAND and SPEED. Its outputs are the 4 sequential signals (SAA, SBA, SAB and SBB) to control the way stepper motor work.

1.2.1 A command input consists of 2 switches, i.e., SW1 and SW2. Based on the combination of these two switches, the stepper motor can operate based on the following operation modes: MODE 0 1 2 3 SW1 OFF OFF ON ON SW2 OFF ON OFF ON Description Motor rotates counter clockwise. Motor rotates counter clockwise. Motor rotates clockwise. Motor rotates:
1. 120-degree clockwise 2. Then 120-degree counter clockwise (go back to the original position). 3. Repeat 1 and 2 until other mode is selected.

1.2.2 Applied as speed control, switch SW3 is used to select between EXCLK and INCLK. EXCLK is an external clock signal supplied from an external function generator, and INCLK is a clock generator circuit designed by the competitor. 1.3 Design INCLK circuit The competitor will design a square wave generator called INCLK, whose output frequency can be varied from 1 Hz to 200 Hz. 2. Design of Printed Circuit Board (2 Hrs) The competitors will design a single-side PCB based on their designed schematic which has drawn in Hardware Circuit Design part. 3. Build and Test Designed Prototype (2 Hrs) 3.1 Assemble the designed PCB using the components, which already selected in Hardware Circuit Design. 3.2 Test the function of the designed PCB

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Pertandingan Kemahiran Malaysia (PKM)

The project should be assembled by referring to IPC-A-610 issue D International acceptability of electronic assemblies. Each project may fit a Euro card standard using DIN 41612 connectors that will fit a standard back plane connector. Supplies and I/O signals are as follows: Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Signal of A line +5V Digital N/A Digital Ground EXCLK INCLK SAA SAB SBA SBB N/A N/A N/A +5V Analog N/A +12V Analog Analog Ground -5V Analog -12V Analog N/A L1 L2 L3 L4 N/A N/A N/A N/A N/A N/A N/A Digital Ground +5V Digital Signal of C line +5V Digital N/A Digital Ground EXCLK INCLK SAA SAB SBA SBB N/A N/A N/A +5V Analog N/A +12V Analog Analog Ground -5V Analog -12V Analog N/A L1 L2 L3 L4 N/A N/A N/A N/A N/A N/A N/A Digital Ground +5V Digital

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Pertandingan Kemahiran Malaysia (PKM)

MECHANICAL SPECIFICATION

The Europe format for PCB card is specified as follow (PCB only):

All Dimensions are in millimeters. tc = 160 mm

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Pertandingan Kemahiran Malaysia (PKM)

PROVIDED MATERIALS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Qty 2 2 2 2 2 2 2 2 2 3 1 4 1 1 3 1 1 1 1 DIN-64CPBCES 1 100K 1 200K 1 500K 1 1M Part name CD4001 CD4011 CD4013 CD4027 CD4069 CD4070 CD4071 CD4077 CD4081 CD4093 LM7805 IRFZ44 LM555 SMJ40-48 Description CMOS NOR GATE CMOS NAND GATE CMOS D FLIP FLOP CMOS J-K FLIP FLOP CMOS NOT GATE CMOS XOR GATE CMOS OR GATE CMOS XNOR GATE CMOS AND GATE CMOS NAND GATE LINEAR REGULATOR MOSFET TIMER 12V Unipolar STEPPER MOTER 48 Steps/Round SLIDE SWITCH POWER CONNECTER EXTERNAL CLOCK CONNECTOR STEPPER MOTER CONNECTOR MALE DIN CONNECTOR VARIABLE RESISTOR VARIABLE RESISTOR VARIABLE RESISTOR VARIABLE RESISTOR Standard RESISTOR Standard CAPACITOR Notes

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Pertandingan Kemahiran Malaysia (PKM)

DESIGNED RESULTS 1. Draw the designed circuit (7805 circuit) and measure the output voltage.

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Pertandingan Kemahiran Malaysia (PKM)

2. Draw the control signal generator designed schematic (exclude INCLK, driver and stepper motor circuits)

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Pertandingan Kemahiran Malaysia (PKM)

3. Design the internal clock (INCLK) circuit Notes: Show the calculation Draw the designed INCLK circuit Label all component value 3.1 Measure minimum frequency of internal clock (INCLK) circuit. Save the waveform on storage oscilloscope 3.2 Measure maximum frequency of internal clock (INCLK) circuit. Save the waveform on storage oscilloscope

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