HAMDARD UNIVESITY

PROJECT REPORT

ATLAS HONDA LDT.

PREPARED BY THE STUDENTS OF HAMDARD UNIVERSITY

ENGR. MUHAMMAD TAYYAB. ENGR. AWAIS YASEEN. ENGR.SHHBAZ IQBAL. ENGR. OSAMA IFTEKHAR.

Project report

Atlas Honda

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Acknowledgement
First and foremost our greatest thanks to the Almighty Allah for providing us such a great opportunity to have been able to perform an internship in such a prestigious and renowned industry as Atlas Honda. Secondly we would also like to thank Atlas Honda for giving us the time and teaching us what and how are the true aspects of learning being used and applied in the real world. The success and final outcome of this project required a lot of guidance and assistance from many people and we are extremely fortunate to have got this all along the completion of our project work. Whatever we have done is only due to such guidance and assistance and we would not forget to thank them. We respect and thank Mr. Mohammed Saeed and his department of frame assembly in Atlas Honda for providing all the information, and support and guidance which made us complete the project on time. We are extremely grateful to him for providing us such a nice support and guidance though he had busy schedule managing the company affairs. We owe our profound gratitude to Mr. Syed Sajjad Ali of maintenance department in Atlas Honda, who took keen interest on our project work and guided us all along, till the completion of our project work by providing all the necessary information for developing a good system. We also would not forget to remember Mr. Ali of maintenance department for his unlisted encouragement and more over for his timely support and guidance till the completion of our project work. Last and certainly not the least we are thankful to Atlas Honda staff and management from which we are fortunate enough to get constant encouragement, support and guidance from all the staffs of each and every department which helped us in successfully completing our project work. Let us thank again to our supervisors Muhammad Saeed, Syed Sajjad and Ali. We want to show more gratitude towards ENGR. Sajjad who helped us in this project. Engr. Osama Iftikhar. Engr. Mohammed Tayyab. Engr. ShahbazI qbal. Engr. Awais Yaseen.
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Introduction:
The name Atlas Honda needs no introduction. Since its inception, more than 50 years ago it has been a symbol of greatness in Pakistan, not only due to its renowned name but it is also because it provides the comfort to its customers in its services. To keep the interest of public in its products, like any other industry Atlas also requires precision and quality in its products which therefore requires heavy, accurate and up to date machineries. Although by bringing in heavy machinery you resolve your problem but after sometime it starts to wear out its performance, in other words it requires maintenance. Our problem or our assigned task is actually not a problem but a replacement solution which could be applied for a given period of time in case of emergency which is to provide a solution for frame assembly paddle switch which causes sometimes mechanical problems and countings etc.

Problem Identification:Usually in any industry, to assemble a product or an item each men is assigned to a specific task and after some process we get the shape or model of our required item. For this we require machines to do the tasks and provide production at a much faster and more efficient rate. In the frame assembly department of Atlas we have a frame assembly conveyer, where CD-70 is assembled by joining its frame with engine, fender, drum, wheels, lights, battery etc. After a bike is fully assembled it passes to peizo-electric switch which is connected with a counter. Each time when a bike front wheel is passed, a 30 second delay occurs whereas the counter counts +1 that a bike is assembled. Peizo-electric switches are pressed by mechanical stress and provide excellent precision for counters but after some time as it wears off its performance. Our problem lies there that sometimes when a bike is passed the paddle at which the switch is placed stays pressed making one more count than our requirement.

TASK:Our assigned task as described by the title of our project, we have to replace this paddle switch with a more efficient solid state device. This task does not have one but multiple solutions but we are trying to provide a solution which is in our aspect, the most optimum solution among them all. There is number of sensors that we can use which can sense a motorcycle and operate increment to counter display. But we have made criteria on which we select the sensor. But this is not hard and fast rule. It is just for our ease.
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First of all we have to imagine the solution in our mind. We have thinked about it and develop a block diagram which is also called the flow diagram, on which we have to work. We have found the solution in this flow. The block diagram is given below.

IR-TRANSMITTER

IR-RECIEVER

DELAY CIRCUIT

COUNTER CIRCUIT

ACT AS A SWITCH

DISPLAY

We can use the techniques given below. Proximity sensor. Metal detector. Image processing (through camera). Limit switch. Pressure sensor. Infra red sensor. These all are the techniques that we can implement in our project. But according to our criteria (given below) INFRA-RED SENSOR is prefect sensor.

CRITERIA TO CHOOSE SENSOR: First of all we have to study about efficiency of that sensor. We have to check that what will be the input and what will be the output. It must be less power consumer. Should be easily implementable.

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Atlas Honda

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Sensor circuit should be as small as possible. Because if more components required, chances of efficiency lose increase because any component can be damage or maybe there is a loose connection problem take place. Sensor must be easily available in the market. Cost is one of the most important factors in this thesis. Sensor must be of low cost.

According to above criteria we described, we decided to select INFRA-RED TRANSMITTER AND RECIEVER circuit. All the requirements described above are fulfilling in this solution. The other sensor are also applicable, but having some problems with them. Therefore we are not interested in those sensors.

INFRA-RED SENSOR:Infrared is most commonly used in this type of projects specially for counting purposes. It has two circuits, one is called transmitter circuit and other is called receiver. These both are placed apart from each other. Transmitter continuously transmits infra-red light which is invisible by human eye. On the other hand, receiver receives these light rays continuously. If any interruption occurs between them, receiver do not receives the signal, and then it produces output. This output is in the form of electric voltage signal which is amplified, then connected to the output circuitry. The transmitter is give below.

IR TRANSMITTER

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Atlas Honda

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This transmitter is nothing, but an oscillator which produces the square wave with a frequency of approximately 10 KHz which we are giving as an input to IR-LED shown in figure. The frequency can be change by changing the values of R1 (Resistor 1), R2 (Resistor 2) and C1 (Capacitor 1).This IR-LED is transmitting infra-red light toward receiver which is receiving it continuously.

IR-RECIEVER The above circuit diagram is called IR-Receiver circuit. Three pin device named IR-RECIEVER which is continuously receiving the infra red light coming from the transmitter. If there is any interruption between the transmitter and receiver, the receiver cannot receive the radiations, and hence produce the output. Any load can be attached here at output; it may be an LED, a speaker, an alarm, a motor, display etc. This transmitter and receiver will work just as a switch.

DELAY CIRCUIT:In the above block diagram, a delay circuit is connected. Here the explanation is required for this. This delay circuit is use to perform a delay of few seconds (approximately 30 seconds. It gives delay after every count. When the signal is counted, this circuit disables the counter for a specific time. Before this time, counter doesnt work. This work is must for efficiency. Because one motorcycle interrupt the IR-Light more than one time. The example of tyres is valid here. When one tyre passed through then second will also has to pass through same line. Due to this dual interruption, counter will count more than one on a bike. We have to count one motorcycle at a count. The other prevention is that the counter counts multiple counts by applying a single input. This is due to bouncing of mechanical switch. But here is not mechanical switch, but problem like
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that is present. To avoid this problem, we use this circuit. This is also called the de-bouncing circuit. It force to the counter to count only one time in a defined time. The defined time can be change by changing the values of R (Resistor) and C (Capacitor).

DE-BOUNCING CIRCUIT

COUNTER CIRCUIT:Counter circuit is the most important of this project which can count number of motorcycles are passing through out. There are different ways of counting objects. But we have used here we have used HCF4026B IC. This IC is manufactured by CMOS technology. As we all know that
the CMOS advantages over TTL ICs. These (CMOS) are less power consumer ICs. Another advantage of HCF4026B IC is that, it is a dual purpose IC. It count as well as decode the signals for a seven segment display. It has the property of cascading with other similar ICs. Some more features of this IC are given below.
COUNTER AND 7-SEGMENT DECODING IN ONE PACKAGE.

EASILY INTERFACED WITH 7-SEGMENT DISPLAY TYPES. FULLY STATIC COUNTER OPERATION : DC TO 6MHz (Typ.) AT VDD = 10V IDEAL FOR LOW POWER DISPLAYS.

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Atlas Honda

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DISPLAY ENABLE OUTPUT.

The circuit of counter is given below

COUNTER CIRCUIT

CIRCUIT DESCRIPTION:In the above counter circuit, HCF4026B IC is used as a counter. This IC works as a counter as well as a display driver for seven-segment displays. In this circuit, there are three ICs are used for three displays. These ICs are cascaded with each other. The top most segments is the unit, the middle one is the TENs, and the last one is HUNDREDS. So, this counter can count and display till 999. After these figures, it takes starts from zero.
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If we want to reset the displays, we can do this by pressing SWITCH 2 in the circuit. through this switch, we can start the counting from zero. Here the SWITCH 1 will be the infra-red objector detector. When input appears, the counter will count and make increment on displays.

SOFTWARE:The software we have used is protius 8 professional. Through this, we have checked counter circuit which was working properly.

CONCLUSION:This project is valid for any type of counting, even you can count your products, you can count visitors visited by the company, no. of employees entered to the department and many more similar applications. It can show you the no. of counts at display. This circuit can be used as a timer circuit, by just connecting an astable multivibrator at input clock.

Project report

Atlas Honda

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