ADDIS ABEBA SCIENCE AND TECHNOLOGY

UNIVERSITY

ELECTROMECHANICAL ENGINEERING

INTERNSHIP PROJECT

PROJECT TITLE: AUTOMATIC SWITCH FOR

MOTOR

PREPARED BY: GELETA GIRMA

SUBMITTED To: Melaku Desta

 June 2016

Table of content

Title
page
1. Problem statement
2. Abstract
3. Introduction
4. Objective
5. Hypothesis
6. Project contribution
7. Project limitation
8. Theoretical framework
9. Literature review
10. Methodology
11. Budget for the Project
12. The project duration and schedule
13. Nomenclature
14. Abbreviations
15. References
16. Recommendation

Problem statement
1 The problem of motor switches in managing the variation of power from the source.

2 Cost for rewinding the motors

3 The quality of rewinding motors less than the previous one.

Abstract
 In our country Ethiopian there is mostly no simple control system for
motors, because of this we have face a lot of problem. Motors always
burned because of electric power variation from the source. So this small
project proposal I have planned to build simple Automatic switch control
system for motors in the company. For winding of a motor a lot of many
wasted. The best solution for this is keeping the motors in safe way.

This automatic switch control system function by using sensor,

microcontroller, switch like triac, filter and same passive device. This
project will be done by using complex switch control system as model and
make it simple by extracting components but both govern by same
principle we expect the project to solve problem which caused by lack of
switch control system and income , machine life , time of production
...etc.

Introduction
Most problem of motor can be solved; if we control the speed of the
motor on the machine with automatic switch. As we know induction motor
in flour factories main part or it is 'heart' of the machine. So if we can
manage speed of induction motor. We can solve all most all problems
which are caused by this motor in the factories.

In our world we have many complex speed control system for motor
especially for dc motor like Brushless dc motor ,servo motor ...etc. But we
don't have simple automatic switch control system for induction motor. At
the moment almost all experiment are focused on making sophistication
instead of making a simple Automatic switch for small sector which use
motor like ''wefcho bet'', onion grinding house, motor winding sector...etc.

So in this project proposal we plan to build simple automatic switch

control system.. This will be done from the complex control system model
but the working principle is the same and to minimize the cost of control
system with high efficiency and solve the whole problem caused by lack of
speed control system like quality, power, machine life, income, health ...
etc.

Objective

To change current mechanical switch with simple automatic switch.

To make simple automatic switch control system for machine in
need of this device.
To increase machine life and to give full data about the machine for
the owner to use for many thing like calculating annual gain and
loss and to control labour outside working.

Hypothesis

I except from the lab result the circuit will be High efficiency.
The TRIAC has Minimum noise.
It will have long working time.
The device operating temperature range of 30-40 C.
We expect theoretically result should be 1-5% tolerance difference
to practical result (the value we get in the lab if the instructor allows
this proposal).
It will minimize human labour.

Project contribution
In this Project we try to increase machine life when the power drop
as you know the speed of the motor also drop so in this
inappropriate speed of motor cause wear of teeth, crack ...etc. so if
we can stop this machine before this happen by using automatic
switch control system we have solved huge disaster
This Project contribute for factories in power consumption
This Project has huge benefit for owner like
by using the memory in the circuit they can calculate annual
benefit and loss
he can predict the machine life
from the memory you can get full information about the
machine like working time so the owner can control the labour
 outside the working place so he don't have to depend on the
behaviour of the labour whether he is cheater or not if you
have memories that tells all about the working place
From I have got practical value anyone who is interested to add
something on this, he shouldn't have to start from scratch he can
use this project as standing stone.
Project limitation
This project used for machine that needs to indicate the use to
shut down (switch off) if there is a problem in the production
otherwise this automatic switch control system is not the
appropriate device
If there is a problem in the production otherwise this automatic
switch control system is not the appropriate device. This project use
c++ program but I write the code and I plan to use microcontroller.

Theoretical framework

Closed loop systems

A closed loop system is a system that uses a measurement of the

output and feedback of the signal to compare it with the desired output
(Reference or command).

In a closed loop control system, the output of the process (controlled

variable) is constantly monitored by sensor as shown in figure. The sensor
samples the system output and converts this measurement into an
electric signal that passes back the controller. Because the controller
knows what the system is actually doing,

It can make any adjustment necessary to keep the output where it

belongs. The signal from the controller to the actuator is the forward path,
and the signal from the Sensor to the controller is the feedback (which
closes the loop).in the feedback signal is subtracted from the set point at
the comparator (just ahead of the controller). By Subtracting the actual
position (as reported by the sensor) from the desired position (as defined
by set point), I get the system error. The error signal represents the
Difference between where you are and where you want to be. The
controller is always working to minimize this error signal. A zero error
means that the output is exactly what the set point says it should be.

The self-controlling feature of closed loop control makes it more

preferable over open-loop control systems provides reliable, repeatable
performance even when the System components themselves (in the
forward path) are not absolutely repeatable or precisely known.

Literature Review
The problem on switch of motor was considered by many investigators
and researchers. Most of the project work concentrated on mechanical
switch system. Few scientific publications are available that concern
automatic switch for big sectors rather for small. The following programs
give a quick summary of the important previous publications.

The first switch employing quick break technology was invented by

John Henry Homel in2000 in shield field district of Newcastle upon Tyne
the quick break switch. overcame the problem of a switching contacts
developing arcing whenever the circuit was opened or closed. The action
of this quick break mechanism meant that there was insufficient time
for an arc to form and the switch would have long working life.

In 2004 William .J Newton design the toggle switch mechanism was

almost quit switch. The quit switch mechanism still possess a form of snap
action but it is very weak as compared to its predecessor. They are
equipped with larger, high quality contacts that are capable of switching
domestic loads without damage, despite the less positive action.

Methodology
The method I plan to use is experiment in lab. By constructing the
circuit and measure the whole parameter which is important to calculate
like:-
 Efficiency
Heat dissipation(P=I^2*R)
Temperature
Filter using oscilloscope and function generator

1) Memory: Storage devices: e.g., memory to store the control

program and the state of the control system obtained from the sensors

It is used to save vehicle speed at each stage

Figure 1 Memory storage

2) Microcontroller: It is the most important component of the circuit.

Microcontrollers usually have special internal register for pulse counting
process the sensory information and compute the control command for
Triac to carry out specified tasks (switch on or off). The microcontroller is
a microprocessor capable of generating steps pulses and direction signals
for the driver (amplifier). It is programmed to control the action of the
motor to perform the necessary operation to limit the working of the
motor. The microcontroller was programmed by the commercial software
"MIKROBASIC" .
 Figure 2 Microcontroller circuit

3) DC Battery (12V): It provides the DC current to the control circuit.

4)Triac is turned ON by the control signal coming from the microcontroller

with some delay after zero crossing and automatically turned off when its
current reach a zero values.

The 'heart ' of this application is the microcontroller which control the
triac . The TRIAC produces a noise when it is turned ON or
OFF ,so the input Electromagnetic interference(EMI) filter should be
connected to the board as well (But it is optional) because when I use in
'wefcho bet' It is a lot noise more than this so it is depend on the situation
to use .

The current flowing through the TRIAC increase its temperature if the
current is to high it is necessary to use a heat sink.
 Figure 3 TRIAC symbol and schematic diagram

5) Filter: used to reduce the noise coming from the board but we
decide this filter is necessary after the proposal has acceptance
effect and I will decide.

6) Screen: It shows the data of the operating conditions.

7)Amplifier: They amplify the signal that comes from the remote-
control unit and convert the microcontroller command signals into the
power necessary to energize the DC motor windings.

8) Encoder sensor: signals are connected to microcontroller like 2

binary sensors (digital input lines).It convert the value of volt into a
parallel digital signal corresponding to a binary coded version of the
decimal number
Figure 4 Encoder sensor using hole

Figure 5 Encoder sensor using colour

Programming of the Microcontroller

The microcontroller was programmed by the commercial software"

MIKROBASIC, V.5.0" [25]. This software was developed as a simple
programming tool of microcontrollers. Its language is similar and has
characteristics of many BASIC implementations with an editing
environment to allow the user to create, test and deploy BASIC programs.
MIKROBASIC
allows math and string operations. Also, a series of commands to control
the program flow and I/O operations are implemented in its interpreter
engine. Generally, the software disk contains two binaries: "based.exe"
and "mbasic.exe" and a set of example programs. The binary "based.exe"
is the
editor environment and can be used to edit and run MIKROBASIC
programs. The binary "mbasic.exe" is the actual interpreter engine and it
is necessary to run the developed programs. The software engine is
automatically called by the editor environment. Such functionality makes
very easy to develop and test applications inside the editor environment.

Operation Steps of the switch Control

System
The automotive switch control system can be operated by carrying out
these steps:
1. Switching on the electronic circuit.
2. Pressing one of the buttons of the remote-control unit.
3. The signal is received to the electronic circuit by the receiver and
amplified by the amplifier.
4. The microcontroller compares the previous value of speed that is stored
in the circuit memory with the new value that was received from the
remote-control unit.
5. As a result of this comparison, the microcontroller gives the correct
order to the motor to rotate by the proper amount. This order is given
based on the
pre-programming of the microcontroller
6. The microcontroller checks the new position and makes necessary
adjustments until reaching the correct pre-set
 Budget for the project

N Material No of material Cost(birr)

o
1 Resistor 4 25
2 Capacitor 3 20
3 TRIAC 1 55
4 Inductor 3 10
5 Battery(5volt) 2 15
6 Wire(1meter) 2 20
7 Soldering iron(1 meter) 1 15
8 Microcontroller(MLT002N3000B5 2 500
C)
9 Screw 7 10
10 Motor 1 110
11 Encoder sensor 1 50
Table 1 Material for the circuit

From the table we see it need 1200 birr to build the circuit. (The current )
 Equipment or tools I need for the circuit
1) Oscilloscope
2) Function generator
3) Digital Malty meter
4) Screw Driver
5) Soldering
6) Drill
7) Tape (white and black)

The project duration and schedule

N Time duration Task

o
1 4 days Collecting material and buy
2 1 days Build the circuit
3 3 days Collecting data and data analysis
4 2 days Compare theoretical result with
experiment result
5 1 day Result
6 4 days Discussion
7 1 days Conclusion
8 5 days Manual for the circuit

Table 2 Time duration need for the project

So we need three week to complete this project and to give the

result of the model for production. And it takes less an hour for
assembly of the switch for motors.

Nomenclature
I current
R Resistor
C Capacitor
V Volt
P Power
C Degree Celsius

Abbreviations
 DC Direct Current
RPM Engine rotational speed
IR Infrared Waves
PLC Programmable Logic Controller
LED Light emitting diode

Recommendation
In most factories motors need more power than other devises need
power. If motors able to use low power in the factory; it may save a
lot of many. Using automatic switch for factories is the best way for
company owner. The switches that current factories use are more
available for damages of motor.

References

Ahmed Farouk AbdelGawad and Talal Saleh Mandourah (2014) Proposed Simple
Electro-Mechanical Automotive Speed Control System. American Journal of
Aerospace Engineering.vol 2, pp. 1-10.

Richard C.Dorf and Robert H.Bishop (2008), Modern Control Systems,Pearson

Prentice Hall, United States of America.

Thomas L.Floid (2006) Digital Fundamentals, Pearson Prentice Hall, United

States of America.

Thomas L.Floid (2012) Electronics Devices,Pearson Prentice Hall, United States

of America.

Xianyan Hu,Hongping Zhu and Dansheng Wang(2014)A Study of Concrete

Slab Damage Detection Based on the Electromechanical Impedance Method,
Sensors,Huazhong University of Science and Technology,China.