Remote Controlled Fan Regulator

1.    INTRODUCTION

A circuit that allows total control over your equipments without having to move around is a revolutionary concept. Total control over the speed of the fan is a boon to many. This product brings to you this very concept.

Remote control facilitates the operation of fan regulators around the home or office from a distance. It provides a system that is simple to understand and also to operate, a system that would be cheap and affordable, a reliable and easy to maintain system of remote control and durable system irrespective of usage. It adds more comfort to everyday living by removing the inconvenience of having to move around to operate a fan regulator. The system seeks to develop a system that is cost effective while not under mining the need for efficiency. 

The first remote control, called “lazy bones” was developed in 1950 by Zenith Electronics Corporation (then known as Zenith Radio Corporation). The device was developed quickly, and it was called “Zenith space command”, the remote went into production in the fall of 1956, becoming the first practical wireless remote control device.

Today, remote control is a standard on other consumer electronic products, including VCRs, cable and satellite boxes, digital video disc players and home audio players. And the most sophisticated TV sets have remote with as many as 50 buttons. In year 2000, more than 99 percent of all TV set and 100 percent of all VCR and DVD players sold are equipped with remote controls. The average individual these days probably picks up a remote control at least once or twice a day.

Basically, a remote control works in the following manner. A button is pressed. This completes a specific connection which produces a Morse code line signal specific to that button. The transistor amplifies the signal and sends

it to the LED which translates the signal into infrared light. The sensor on the appliance detects the infrared light and reacts appropriately.

The remote control’s function is to wait for the user to press a key and then translate that into infrared light signals that are received by the receiving appliance. The carrier frequency of such infrared signals is typically around 36 kHz .

 One of the primary objectives of an engineer is to endeavor to deliver the best product or the most efficient services at the lowest cost to the end user. The system was found to meet the expected results. 

 The aim of this work is to design and construct a remote control for a fan regulator.. The remote control device sends an infra-red beam, which is received by the infra-red sensor on the regulator and the fan also increases in speed.

2.    BLOCK DIAGRAM





 

3.    BLOCK DIAGRAM DESCRIPTION

Infrared Receiver Module

             Here TSOP 1738 is used as infrared receiver Module. The infrared rays transmitted by the remote control in received by TSOP 1738. it is capable of receiving signals up to 38 KHz.

Monostable Multivibrator 

            Here NE 555 IC is wired as monostable multivibrator. The trigger to this is signals from receiver module. Monostable multivibrator is used forgetting a accurate pulse.

Decade Counter 

            CD 4017 is used as decade counter. Here actually ten outputs are there from which five are used (Q0 to Q4), Q5 is not used and Q6 is used to reset. The output of monostble is used to delay the clock pulse of decade counter. 

Regulator Section 

            The 230 V Ac us step down to 12 V by transformer (12V-0-12V). This 12V is regulated wring IC 7809 to 9V. This 9V is supplied to the whole circuit. 

Opto Coupler.

             MCT2E is used as optocoupler. It is used to trigger the monostable multivibrator. 

Opto Isolator

            MOC  3021 is used as opto isolator. It is used to drive the Triac BT 136.

Triac

            It is thyristor with a firing angle nearly 450. A snubber circuit consisting of a resistor and capacitor is used to control the firing angle of Triac. This firing angle determines the speed of the fan. 

4.    CIRCUIT DIADGRAM

5.    WORKING OF CIRCUIT

            The 230 V from AC mains is stepped down to 12V and Regulated by IC 7809 and, capacitor and Diodes to 9V. This filtered 9V is used for proceeding supply to the entire circuit. Any button of remote control can be used to control the speed of the fan. The remote control produces infrared rays which is received by the TSOP infrared receives module. The TSOP used here is TSOP 1738. It is capable for receiving signals up to 38 KHZ. The infrared rays received by the TSOP senses it and its output is wired as a trigger to the first monostable multivibrator NE 555 through a LED and Resistor R4.

 This NE 555 which is wired as Monostable multivibrator is used to delay the clock to decade counter which is CD 4017. We can directly give the output of TSOP to decade counter, but white doing so all the small pulse or noises may also act a clock to counter and counter starts counting. The decade counter has ten outputs from Q0 to Q9. But here we are using only Q0 to Q4. Q5 is not used and Q6 is used to reset the counter. The outputs of decade counter is taken through Resistors R5 to R9. The resistor Rs to R9 and capacitor C5 controls the pulse width which is actually determining the speed of the fan high capacitor C% is charged through R6 and so on. Here we are controlling the speed of the fan.

 When the output of Q0 is high the capacitor C5 is charged through R5, if Q1 is high capacitor C5 is charged through R6 and so on. Here we are controlling the speed of the fan in five levels that is why we are taking five outputs (A0 to Q4).

 Another NE 555 used here which is also wired as monostable multivibrator. This monostable is triggered by pulses from out coupler MCT 2E. It is wired as Zero crossing detector. The output from decade counter is given to NE555 and this is given to the transistor BC 548 it is given to the Opto isolator MOC 3021. It is used for driving the Triac BT 136. Triac is a

type of thyristor. Here the resistor R13 (470hm) and capacitor C7 (0.01µF) combination is used as snubber network for the Triac.

 By the controlling done by Resistors R5 to R9 and capacitor C5 we can control the pulse width. When Q0 output is high the pulse width is maximum, when Q1 output is high pulse width is decreased slightly. As the pulse width decreases firing angle of the triac increases and speed of the fan also increases. By using remote control we are actually controlling pulse width which in turn vary the firing angle of triac, which inturn vary the speed of the fan.

                            

6.    COMPONENTS LIST

1. TSOP 1738
2. IC NE 555
3. IC MCT2E
4. IC MOC 3021
5. IC 7809
6. IC CD4017

7. TRANSFORMER 12V -0-12V
8. LED
9. DIODE . IN 4007
10. TRANSISTOR BC548
11. TRIAC BT 136
12. CAPACITORS
          0.01 µF /400V
          4.7 µF /16V
          10 µF /16V
          1 µF /16V
          0.22µF
          470 µ /50V

13. RESISTORS
          1K Ω
          100K Ω
          330Ω
          47K Ω
          33K Ω
          27K Ω
          20K Ω
          12K

     

    3.3K Ω
    470 Ω       

5.6 K Ω
          10 K Ω
          47 Ω
14. ZENER DIODE5.1V

7.    Description of the Components

TSOP 1738

DESCRIPTION

The TSOP17..- series are miniaturized receivers for infrared remote control systems. PIN diode and preamplifier are assembled on lead frame, the epoxy package is designed as IR filter.

The demodulated output signal can directly be decoded by a microprocessor.TSOP17 is the standard IR remote control receiver series supporting all major transmission codes.

Features

·         Photo detector and preamplifier in one package

·         Internal filter for PCM frequency

·         Improved shielding against electrical field disturbances

·         TTL and CMOS compatibility

·         Output active low

·         Low power consumption

·         High immunity against ambient light

·         Continuous data transmission possible (up to 2400 bps)

·         Suitable burst length >= 10 cycles/burst

IC NE 555

Description

          The NE555 is a highly stable controller capable of producing accurate timing pulses .With a monostable operation, the time delay is controlled by one external resistor and one capacitor .With an astable operation. The frequency and duty cycle are accurately controlled by two external resistors and one capacitor

.Its applications are precision timing , pulse generation , time delay generation , sequential timing etc.

FEATURES

·         High current drive capability (200mA)

·         Adjustable duty cycle

·         Temperature stability of  0.005%/ ˚C

·         Timing from µsec to hours

·         Turn off time less than 2µsec

IC MCT2E

DESCRIPTION

          The MCT2E is an NPN silicon planar phototransistor optically coupled to a gallium arsenide infrared emitting diode. Its applications are power supply regulators ,digital logic inputs microprocessor inputs.

FEATURES

·         UL recognized

·         VDE recognized

IC MOC 3021

is "an

 e

Schematic diagram of an opto-isolator showing source of light (LED) on the left, dielectric barrier in the center, and sensor (phototransistor) on the right.

In electronics,an opto-isolator, also called an optocoupler, photocoupler, or optical isolator, lectronic device designed to transfer electrical signals by utilizing light waves to provide coupling with electrical isolation between its input and output". The main purpose of an opto-isolator is "to prevent high voltage or rapidly changing voltages on one side of the circuit from damaging components or distorting transmissions on the other side." Commercially available opto-isolators withstand input-to-output voltages up to 10 kv and voltage transients with speeds up to 10 kV/μs.

An opto-isolator contains a source (emitter) of light, almost always a near IR light emitting diode (LED), that converts electrical input signal into light, a closed optical channel (also called dielectrical channel), and a photo sensor which detects incoming light and either generates electric energy directly, or modulates electric currents flowing from an external power supply. The sensor can be a photoresistor a photodiode, a phototransistor, a silicon controlled rectifier(SCR) or atriac.Because LEDs can sense light in addition to emitting it, construction of symmetrical, bidirectional opto-isolators is possible.

IC CD4017

The 4017 IC is a 16-pin CMOS decade counter from the 4000 series. It takes clock pulses from the clock input, and makes one of the ten outputs come on in sequence each time a clock pulse arrives.

	Name	Purpose
1	6	The 6th sequential output
2	2	The 2nd sequential output
3	1	The 1st sequential output
4	3	The 3rd sequential output
5	7	The 7th sequential output
6	8	The 8th sequential output
7	4	The 4th sequential output
8	0 V, VDD	The connection to the 0 V rail
9	9	The 9th sequential output
10	5	The 5th sequential output
11	10	The 10th sequential output
12	CO	Carry out output - outputs high on counts 0 to 4, outputs low on counts 5 to 9 (thus a transition from low to high occurs when counting from back to 0)
13	LE	Latch enable - latches on the current output when high (i.e. the chip counts when LE is low)
14	CLK	Clock in
15	RST	Reset - sets output 1 high and outputs 2 through 10 low, when taken high
16	+9 V, VCC	The connection to the +VCC rail (voltage between +3 V and +15 V)

TRIAC BT 136

TRIAC, from Triode for Alternating Current, is a generic zed trademark for an electronic component which can conduct current in either direction when it is triggered (turned on), and is formally called a bidirectional triode thyristor or bilateral triode thyristor.

A TRIAC is approximately equivalent to two complementary unilateral thyristor joined in antiparallel(paralleled but with the polarity reversed) and with their gates connected together. It can be triggered by either a positive or a negative voltage being applied to its gate electrode (with respect to A1, otherwise known as MT1). Once triggered, the device continues to conduct until the current through it

drops below a certain threshold value, the holding current, such as at the end of a half-cycle of alternating current(AC) mains power.

This makes the TRIAC a very convenient switch for AC circuits, allowing the control of very large power flows with miniampere-scale control currents. In addition, applying a trigger pulse at a controllable point in an AC cycle allows one to control the percentage of current that flows through the TRIAC to the load.

TRANSISTOR BC548

The BC548 is a general purpose silicon npn transistor. The BC546 through BC550 are NPN silicon planar epitaxial transistors for using AF small signal amplifier stages and direct coupled circuits. They are complimentary to BC556 through BC560. The BC548, BC550 are characterised by low noise figure. As a representative of the large family of bipolar transistors the BC548 provides a "stepping off point" to the use of more esoteric, higher voltage, current or frequency devices for beginners. If the TO-92 package is held in front of one's face with the flat side facing toward you and the leads downward, (see picture) the order of the leads, from left to right is collector, base, emitter.

8.    PCB FABRICATION

Printed circuits boards play a vital role here in determining the overall performance of electronic equipment .A good PCB design ensures that the noise introduced as a result of component placement and track layout is held within limits while still providing components years of assembly maintenance and performance reliability.

WHERE AND WHY ARE PCB’S USED?

 Printed circuits boards are used to route electric signals through copper track which are firmly bonded to an insulating base. Advantages of PCB over common wiring are 1. PCB’s are necessary for connecting a large number of electronic components in a very small area with minimum parasitic effects. 2. PCB’s are simulated with mass production with less chance of writing error3. Small components are easily mounted. 4. Servicing in simplified. The base materials used for PCB’s are glass epoxy, epoxy paper, polyester etc.Copper foil used for copper clad is manufactured by the process of electronic deposition .The properties of copper foil are:  Thickness………………35μ meter  Thickness tolerance……+5 μ meter  Purity of Copper………99.8%  Resistivity at 20◦C…….0.1594PREPARATION OF SINGLE SIDED PCB  In a single sided PCB the conductor tracks run only on one side of copper clad board. Thus crossing of conductors is not allowed. Base materials are selected according to application. It is mechanically and chemically cleansed. Then the photo resist is an organic solution which when exposed to light of proper wavelength, changes their solubility in developer but after exposure to light is not soluble. Laminate coating of photo resist is done by (i)spray coating (ii)Dip coating (iii)Roller coating. The coated copper clad and laminated film negative is kept in intimate contact with each other.

The assembly is exposed to UV light and exposed board is rinsed in the developer tank. Proper developer has to be used for a particular photo resist and then the PCB is dyed in a tray. The dye reveals the flux to be used for a particular photo resist. Then the PCB is dyed in a tray. LAYOUT  The layout can be done either by hand or by using PCB designing software like ORCAD or PROTELFABRICATION  The required circuit is designed and  the layout of the circuit is done on the component side as well as the copper clad side. Spaces are provided for holes to insert the respective components. Etch resistant ink coatings are given on the interconnecting marks ETCHING the copper clad PCB is etched with ferric chloride solution containing a small amount of Hydro Chloric Acid for increasing activeness of Ferric Chloride in etching. Wherever the varnish coating is there the copper remains. Then it is washed with water and Oxalic AcidDRILLING.  The required holes are drilled using twist drill. Now the PCB is complete and ready for soldering.SOLDERING Soldering is the process of joining of two metals using an alloy solder consisting of Tin and Lead (Sn-Pb). Tin determines the melting whereas the Lead is used to reduce the cost. After the PCB fabrication is done, the various components are arranged at proper locations on the PCB and then the soldering is done all liquids consist of particles which attract each other. The surface is always is trying to shrink and this is because of surface tension. The principle behind soldering is that when liquid particles are brought in contact with the walls of the solid surface, it may happen that the solid attracts the liquid surface. This property is called adhesive property. Care must be taken that the melting point of solder is below that of the metal so that its surface is melted without melting without the metal. NEED FOR FLUX. During the soldering process the flux acts as a medium for improving the degree of melting. The basic functions of flux are mentioned below1. Removes oxide from the surface. 2. Assists the transfer of heat from the source to the joining and provides a liquid cover including air gap3. Removal of residue after the completion of the soldering operation

9.    PCB LAYOUT

   

COMPONENT VIEW

      

10.     APPLICATION

 Remote controlled Fan Regulator is used to control the speed of fan from our bed or couch. The same circuit finds its use to control the Intensity of light at fire levels. So it can be used as night lamps. This circuit also finds it use for switching ON and OFF any electronic circuit.

11.  ADVANTAGE

 This circuit is simple to use and efficient. It can be assembled with ease. It is cheap and hence and very economic. It is small in size and can be fixing inside the fan. 

12.  DISADVANTAGE

  The one and only one disadvantage of the circuit is that speed can be increased only in one direction. It can’t be decreased.

13.     .CONCLUSION

            With the knowledge of new techniques in ‘Electronics’ we are able to make our life more comfortable one such application of electronics is used in “REMOTE CONTROLLED FAN REGULATOR”.

              This same circuit find its use in many more applications. By this the intensity of light can be controlled using remote control. The intensity of light can be controlled in five levels from off position to maximum intensity possible. So it finds its use as night lamp by keeping the intensity of lamp in low level. The circuit also finds its use for switching ON and OFF any electronic circuitry. Our normal T.V remote can be used for controlling speed of fan or intensity of light. So it is very useful or a real help to old age and sick people, since they can control the speed from the place where they are sitting.  We feel that our product serves something good to this world and we like to present it before this prosperous world.