A Project Stage-I Report

On

Password Based Circuit Breaker Control

Submitted By
VIJAY ADIK NIMUNKAR (4158)
ANUSAYA MAROTIRAO DUBAKWAD ( 4159)

Submitted in the partial fulfillment of the requirement

For the award of

Degree of Bachelor of Engineering

Under The Guidance of

Prof. N.N.GHUGE

DEPARTMENT OF ELECTRICAL ENGINEERING

JSPM’S BHIVARABAI SAWANT INSTITUTE OF TECHNOLOGY &
RESEARCH, WAGHOLI, PUNE - 4122 07
Academic Year: 2020- 2021

Affiliated To

Savitribai Phule Pune University

 Password Based Circuit Breaker Control

JSPM’s
BHIVARABAI SAWANT INSTITUTE OF TECHNOLOGY & RESEARCH,
WAGHOLI, PUNE, 412207

Department of Electrical Engineering

CERTIFICATE
This is to certify that the project work entitled “Password Based Circuit Breaker

Control” submitted by

Vijay Adik Nimunkar (4158)

Anusaya Marotirao Dubakwad ( 4159)

is a record of bonafide work carried out by them in the Department of Electrical Engineering,
BHIVARABAI SAWANT INSTITUTE OF TECHNOLOGY & RESEARCH, WAGHOLI,
PUNE, under the guidance and supervision of Prof. N.N.Ghuge in the partial fulfillment of
requirements for the degree of Bachelor of Engineering in Electrical Engineering as
prescribed by the Savitribai Phule Pune University, in the academic year 2020-21.

Place: Pune
Date:

PROF. N.N.GHUGE PROF. S. V. NARKHEDE

PROJECT GUIDE PROJECT COORDINATOR

DR. N. N. GHUGE DR. T. K. NAGARAJ

HOD PRINCIPAL

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 Password Based Circuit Breaker Control

DECLARATION

We, hereby declare that the Project titled “Password Based Circuit Breaker Control”
submitted here in has been carried out by us in the Department of Electrical Engineering of
JSPM’S BHIVRABAI SAWANT INSTITUTE OF TECHNOLOGY & RESEARCH
WAGHOLI, PUNE. The work is original and has not been submitted earlier as a whole or in part
for the award of any degree / diploma at this or any other Institution / University. We also hereby
assign to BSIOTR, PUNE all rights under copyright that may exist in and to the above work and
any revised or expanded derivatives works based on the work as mentioned. Other work copied
from references, manuals etc. are disclaimed.

VIJAY ADIK NIMUNKAR (4158)

ANUSAYA MAROTIRAO DUBAKWAD ( 4159)

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ACKNOWLEDGEMENT

Every project is successful largely due to the effort of a number of wonderful people who have
always given their valuable advice or lent a helping hand. We sincerely appreciate the
inspiration; support and guidance of all those people who have been instrumental in making this
project a success.
We would like to express our heartfelt gratitude and regards to our Project Guide, Prof.
N.N.Ghuge Department of Electrical Engineering, for being the corner stone of our project. It
was her incessant motivation and guidance during periods of doubts and uncertainties that has
helped us to carry on with this project.
We would like to thank Dr. N. N. Ghuge, Head of the Department, Electrical Engineering for
providing necessary guidance, support, motivation and inspiration without which this project
would not have been possible.
We would like to extend our special thanks to Dr. T. K. Nagaraj, Principal of Bhivarabai
Sawant Institute of Technology and Research for encouragement and valuable advice.
We would also like to extend our sincere thanks to the Management of Bhivarabai Sawant
Institute of Technology and Research for providing all the necessary infrastructure and
laboratory facilities.
We appreciate all the help extended by the Faculty members of Electrical Engineering
department to complete the project successfully.
Last but not the least special thanks to our family for their support and kindness, Sincere thanks
to all our friends, specially, for their friendship and support throughout.

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ABSTRACT

The project is designed to control a circuit breaker with help of a password only. A keypad is
connected to the project to enter the password. Fatal electrical accidents to the line man are
increasing during the electric line repair due to the lack of communication and co-ordination
between the maintenance staff and the electric substation staff. This proposed system provides a
solution, which can ensure the safety of the maintenance staff e.g. line man. The control to turn
ON/OFF the line lies with the line man only. This system has an arrangement such that a
password is required to operate the circuit breaker (ON/OFF). Line man can turn off the supply
and comfortably repair it, and return to the substation, then turn on the line by entering the
correct password. The system is fully controlled by a microcontroller from 8051 family. A
matrix keypad is interfaced to the microcontroller to enter the password. The entered password is
compared with the password stored in the ROM of the microcontroller. If the password entered is
correct, then only the line can be turned ON/OFF. Activation / deactivation of the circuit breaker
is indicated by a lamp (ON/OFF). Further the project can be enhanced by using an EEPROM for
user to change the password for a more secured system. It can also be interfaced with a GSM
modem for remotely controlling the circuit breaker via SMS.

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FIGURE INDEX

FIG. NO. TITLE OF FIGURE

Fig. No. 3.1 Block Diagram

Fig. No. 4.1.1 Atmega 328P
Fig. No. 4.1.2 Relay module
Fig. No. 5.1 Rectifier Output

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INDEX
Abstract
Figure Index

CHAPTER 1 INTRODUCTION
1.1 Overview
1.2 Objective
1.3 Thesis Structure

CHAPTER 2 LITERATURE SURVEY

2.1 Background Study
2.2 Related Work

CHAPTER 3 METHODOLOGY
3.1 Block Diagram
3.2 Block diagram Description

CHAPTER 4 TOOLS/ PLATFORM

4.1 Hardware Details
4.2 Software Details

CHAPTER 5 DESIGN and IMPLEMENTATION

5.1 Power Supply Design
5.2 PCB Design

CHAPTER 6 RESULTS and DISCUSSION

6.1 Manufacturing steps
6.2 Advantages

CHAPTER 7 CONCLUSION AND FUTURE SCOPE

7.1 Conclusion
7.2 Future Scope

REFERENCES

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CHAPTER 1

INTRODUCTION
1.1OVERVIEW

The project is designed to control a circuit breaker with help of a password only. A keypad is
connected to the project to enter the password. Fatal electrical accidents to the line man are
increasing during the electric line repair due to the lack of communication and co-ordination
between the maintenance staff and the electric substation staff.
This proposed system provides a solution, which can ensure the safety of the maintenance
staff e.g. line man. The control to turn ON/OFF the line lies with the line man only. This system
has an arrangement such that a password is required to operate the circuit breaker (ON/OFF).
Line man can turn off the supply and comfortably repair it, and return to the substation, then turn
on the line by entering the correct password.
The system is fully controlled by a microcontroller from 8051 family. A matrix keypad is
interfaced to the microcontroller to enter the password. The entered password is compared with
the password stored in the ROM of the microcontroller. If the password entered is correct, then
only the line can be turned ON/OFF. Activation / deactivation of the circuit breaker is indicated
by a lamp (ON/OFF). Further the project can be enhanced by using an EEPROM for user to
change the password for a more secured system. It can also be interfaced with a GSM modem for
remotely controlling the circuit breaker via SMS.
The major problem in the power system is the electrical accidents while repairing the
electrical lines due to the lack of communication between the electrical substation and
maintenance staff. This project gives a solution to this problem to ensure line man safety. Also
the load distribution system has been proposed in which sharing of the load is done between
village side and city side.Now a days, electrical accidents of the line man are increasing while
repairing the electrical lines due to lack of communication between the electrical substation and
maintenance staff. This project gives a solution to this problem to ensure line man safety.

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1.2OBJECTIVE

 In this proposed system the control(ON/OFF) of the electrical lines lies with line man.
 This paper is arranged in such a way that maintenance staff or line man has to enter the
password to ON/OFF the electrical line.
 Now if there is any fault in electrical line then line man will switch off the power supply
to the line by entering the password and comfortably repair the electrical line, and after
coming to the substation line man switch on the supply to the particular line by entering
the password.
 Here, there is also a provision of changing the password. circuit breakers are actually
provided as a means of protection to completely isolate the downstream network in the
event of a fault .

1.3THESIS STRUCTURE
Thesis structure consists of 7 chapters.

Chapter 1: INTRODUCTION
This chapter contains Introduction of project, Motivation Behind Topic Selection.

Chapter 2: LITERATURE SURVEY

This chapter explain literature survey. It includes literature review and background study of our
project that is from where we studied about this project.

Chapter 3: METHODOLOGY
This chapter contains the design and development aspects of the project like the basic block
diagram and its description.
Chapter 4: TOOLS/PLATFORM
This chapter contains description of hardware and software tools used.

Chapter 5: DESIGN & IMPLEMENTATION

This chapter introduces details regarding operations of project and algorithm

Chapter 6: RESULTS & DISCUSSION

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This chapter introduces results generated by the system. It consists of simulation results
in the phase 1 of the project.
Chapter 7: CONCLUSION & FUTURE SCPE
This chapter contains Conclusion and Future scope. Some future improvements that can be
made in our project are explained in this chapter.

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CHAPTER 2

LITERATURE SURVEY
2.1 BACKGROUND STUDY
Now a days, electrical accidents of the line man are increasing while repairing the electrical lines
due to lack of communication between the electrical substation and maintanence staff. This paper
gives a solution to this problem to ensure line man safety. In this proposed system the
control(ON/OFF) of the electrical lines lies with line man. This paper is arranged in such a way
that maintenance staff or line man has to enter the password to ON/OFF the electrical line. Now
if there is any fault in electrical line then line man will switch off the power supply to the line by
entering the password and comfortably repair the electrical line, and after coming to the
substation line man switch on the supply to the particular line by entering the password. Here,
there is also a provision of changing the password. circuit breakers are actually provided as a
means of protection to completely isolate the downstream network in the event of a fault . The
demand for electrical energy is ever increasing. Today over 21% (theft apart!!) of the total
electrical energy generated in India is lost in transmission (4-6%) and distribution (15-18%). The
electrical power deficit in the country is currently about 18%. Electric power is normally
generated at 11-25kV in a power station. To transmit over long distances, it is then stepped-up to
400kV, 220kV or 132kV as necessary.The demand for electrical energy is ever increasing , to
overcome this problem Load sharing concept is included. This paper focusing on village side and
city side based on the load demand and the required voltage is transferred from village side to
city side and vice versa.

2.2 RELATED WORK

Security is the prime concern in our daily lives. Everyone needs to be securing as much as
possible. The electric lineman safety system is designed to control a circuit breaker by using a
password for the safety of an electric man. Due to lack of communication between staffs working
in electrical substation and maintenance, vital electrical accidents to linemen are rising during
electric line repair. This proposed system provides a solution that ensures the safety of
maintenance staff, i.e., lineman. Only the line man will be provided with the control of the line
because this system has an arrangement such that a password is required to operate the circuit

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breaker (on/off). The system is fully controlled by a microcontroller from the ARDUINO family.
A matrix keypad is interfaced to the microcontroller to enter the password. The entered password
is compared with the password generated. If the password entered is correct, only then the line
can be turned ON/OFF. The basic idea behind this paper is shown in the following figure.1.To
repair a particular section of the electric supply line, the lineman wants to turn off the supply to
that line. For this, he first put a request to the system, and then the system responds to him using
the LCD display to enter the password. Then the system generates a password and it will be sent
to the phone (the number of which is stored in the program). The password based circuit breaker
can also be implemented in an automatic door locking system for providing high security. And
also can be implemented to control electronic appliances to save power.

Olalekan Oyebola [1], proposed the concept of safety of human life is of paramount importance.
In the high current switching system, switchgear protects an electrical network. However, it is
essential to provide confidence for working engineers during installation work on high voltage
installations. To prevent accidental switching on of switchgear by the unauthorized workforce,
this paper proposed a more life secured switching password-enabled device to inactivate
unauthorized persons from hazardous switching of electrical power installation without the
notice of field engineers. J.Veena et.al [2], proposed the concept of electric line repair due to the
lack of communication and coordination between the maintenance staff and the electric
substation staff.

In order to avoid such accidents, the breaker can be designed such that only authorized persons
can operate it with a password. There is a provision of changing the password. The system is
fully controlled by the 8 bit 8051 microcontroller. The password stored in an EEPROM is
interfaced to the microcontroller. The password can be changed by using keypad any time unlike
a fixed one burnt permanently on to the microcontroller. A relay is used to operate the circuit
breaker, which is indicated by a lamp. If any wrong attempt to open the breaker (by entering the
wrong password) an alert will be actuated, indicated by another lamp.

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S.P. Achrekar et.al[3], proposed the concept of the electric lineman safety system makes use of a
new concept of a one-time password (OTP). It is found that the electrical accidents to the
lineman are escalating during the electric line repair due to lack of communication and
coordination between the staff in maintenance and the electric substation. In order to avoid this,
we are implementing a password based circuit breaker. When the user puts a request the system
generates passwords and a relay switches to turn ON or OFF the circuit breaker. OTP plays a
major role in this system. The one-time passwords mean the generated passwords are different at
each time. These passwords provide total control to the system to turn on or off the supply to
each line. The maintenance staff e.g. lineman has the control to turn ON/OFF the line because
the lineman has to put a request to the system to its working. If there is a problem in any
particular section of the supply line, the staff wants to the turnoff that line and repairs it.

M. Hassan Ali [4], proposed the concept of development and implementation of control system
based Global System for Mobile Communication (GSM) for electrical applications to enable the
complete control of the interface on which it is placed. The GSM module is used for receiving
short message service (SMS) from the user's mobile phone. The system was integrated with a
microcontroller and GSM network interface using Arduino software was utilized to accomplish
the integration. The system is activated when a user sends the SMS to the controller at home
(regarded as Smart Home). Upon receiving the SMS command, the microcontroller unit
automatically controls the electrical applications according to the user's order by proper
switching actions. In other words, it reads a message from the mobile phone and responds to
control the devices according to the received message.

Mallikarjun Hudedmani[5] proposed the request is registered and a password is sent to the
lineman's mobile and to the control panel GSM module for the further work. The password is
entered through the matrix keypad which is interfaced to the Arduino Uno microcontroller. The
entered password is compared with the received password by the control panel GSM receiver. If
the entered password is correct then the circuit breaker ON/OFF and door OPEN/CLOSE feature
is enabled respectively for the lineman to take up repair. Any trespasser attempts to operate the
machine with the wrong password by three times it will display a message in the LCD display

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and a message is sent to the control room regarding unauthorized accessing of the system for
safety reasons.

Yash Pal Gautam [6] proposed this paper focuses on the safety of the lineman while working so
they do not feel the sudden electric shock. A lineman has to deal with live wires very often; the
chances of critical accidents are high. However, with the right amount of coordination among
lineman and substation, a lot of these accidents can be avoided. The paper aimed at providing a
solution that ensures the safety of maintenance staff. Here, as soon as the lineman detects the
fault in the electric line, an SMS will be sent to the substation staff, who would switch off the
line and turn it on when the fault is being resolved, thus reducing the chances of accidents and
saves the power as well. The proposed system is fully operated on a microcontroller. Vijaya

Vikas Ranpise et.al [7] proposed the concept in which GSM based circuit breaker is an
automatically operated electrical switch designed to provide security to the lineman while
repairing the electrical lines. When operated manually, there is an increasing fatal electrical
accident to the lineman during the electric line repairing due to lack of communication and
coordination between the maintenance staff and the electric substation staff. In order to avoid
such accidents, the circuit breaker can be designed such that only authorized person can operate
it with the help of password. Here, there is a provision of changing the password. The system is
entirely controlled by the ATMEGA. By using the GSM module operator also can enter the
password while he is away from the work station and keypad is used to enter the password when
the operator is in work station. A relay is used to open or close the circuit breaker, which is
indicated by the lamp. Any wrong attempt to open the breaker an alert will be displayed on the
mobile screen through the GSM and also display the status on the LCD display.

Tarun Naruka et.al [8] proposed the concept of the password based circuit breaker control
system. It is a system that accesses only a specified password to control the circuit breaker. There
is a provision of changing the password. The system is fully controlled by the 8 bit 8052
microcontroller family which has an 8KB of ROM for the program memory. A matrix keypad is
interfaced to the microcontroller to enter the password while a relay driver IC is used to switch
ON / OFF the loads through relays. The complete circuit is built with an onboard power supply.

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The power supply consists of a step-down transformer, which steps down the voltage 230 V to
12V AC. This 12V AC is converted to DC using a Bridge Rectifier. The ripples present in
unregulated DC voltages are removed using a capacitive filter and it is then regulated to +5V
using a voltage regulator which is required for the operation of the microcontroller and other
components. From this review, it is clear that all these papers are focused on controlling the
electrical lines with the help of a password. Currently, electrical accidents to the lineman are
rising at the time of refurbishment of electrical lines owing to the lack of contact between the
electrical substation and maintenance staff. These papers give a solution to this problem to
ensure lineman safety. The lineman has the entire control (ON/OFF) of the electrical lines.. This
paper is arranged in such a way that maintenance staff or lineman has to enter the password to
ON/OFF the electrical line using RFID tag and reader to ensure the improved control of lineman
safety. Separate passwords are assigned for each electrical line.

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CHAPTER 3
METHODOLOGY
3.1 BLOCK DIAGRAM

Fig No.3.1 Block Diagram

This proposed system provides a solution, which can ensure the safety of the maintenance staff
e.g. line man. The control to turn ON/OFF the line lies with the line man only. This system has
an arrangement such that a password is required to operate the circuit breaker (ON/OFF). Line
man can turn off the supply and comfortably repair it, and return to the substation, then turn on
the line by entering the correct password. Since it has the provision of changing the password,
person can give any password of his will and have his work done safer.In this proposed system
the control (ON/OFF) of the electrical lines lies with line man. This project is arranged in such a
way that maintenance staff or line man has to enter the password to ON/OFF the electrical line.
Now if there is any fault in electrical line then line man will switch off the power supply to the

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line by entering password and comfortably repair the electrical line, and after coming to the
substation line man switch on the supply to the particular In this project 4×3 keypad is used to
enter the password. The password which is entered is compared with the predefined password. If
entered password is correct then the corresponding electrical line is turned ON or OFF. In this
project a separate password is provided to each electrical line. Activation and deactivation of the
line (circuit breaker) is indicated by the load.

3.2 BLOCK DIAGRAM DESCRIPTION

In this project, the power is distributed over two sections. First one is supply unit and second one
is Breaker unit. Supply unit is converted into 5v and is given to microcontroller. During
maintenance maintainer may met with fatal accident. So, for protection of maintainer , relay is
operated by password. This is done with the help of microcontroller. First of all the password is
preset by programming. When we entered the password by the keypad if it is matched by preset
password then the microcontroller sends a signal to trip the password based relay. And again
when maintenance is done, password to be enter and if it matched with preset password, signal is
send by microcontroller and relay ON. Village area and city area run by separate supply voltage.
If the demand needed for either village or city area based on the available power is sharing
between two area .The load demand is occurred, the maintainer entering the password to operate
the switch the load will share,otherwise switch is opened.

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CHAPTER 4
TOOLS/ PLATFORM

4.1 HARDWARE DETAILS

A) Atmega 328P Microcontroller

The arduino Uno is a microcontroller board based on the ATmega328, It has 14 digital
input/output pins, 6 analog input, a 16 MHZ crystal oscillator, a USB connection, a power jack,
an ICSP header, and a reset button. The Uno differ from all preceding boards in that it does not
use the FTDI USB to serial driver chip.”UNO” means one in Italian and is named to mark the
upcoming release of arduino 1.0. The Uno is the latest in a series of USB Arduino boards and
reference model for Arduino platform.
The Arduino Uno can power via the USB connection or with external power supply. External
power can come either from an AC to DC adapter or battery.The board can operate on an
external supply of 6 to 20 volts. If supply with less than 7v, however, the 5v pin may supply less
than five volts and the board may be unstable. The Ttmega328 has 32 KB of flash memory for
storing code .It has also 2KB of SRAM and 1KB of EEPROM. The Arduino software includes a
serial monitor which allows simple textual data to be send to and from the Arduino board, The
RX and TX LEDs on the board will flash when data is being transmitted via the USB to serial
chip and USB connection to the computer. A Software Serial library allows for serial
communication on any of the UNO’s digital pins, the arduino software includes a wire library to
simplify use of the I2C bus. Arduino is open source hardware and software, which are license
under the GNU lesser General public license, which is permitting the manufacture of Arduino
board and software distribution by anyone.

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Fig: No.4.1.1:ATmega 328P

The Arduino are programmed using a dialect of feature from programming language C and C+
+. In addition to using traditional compiler tool chains, the Arduino provide integrated
development environment (IDE) based on processing language project .

B) Relay

Fig No.4.1.2 Relay Module

5 Volts 1-Channel relay module is an interface board that is compatible with Arduino, AVR, PIC,
ARM, etc. This module can work in a high current like AC250V 10A or DC30V 10A. It controls
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larger loads and devices like DC motors, AC motors, and other AC and DC devices with the digital
outputs from controllers and processors. It is a 1-channel relay module, so it can control any 1
device.  Each relay or channel of 1 channel relay module needs 15-20mA driver current and 5
Volts supply.

Product Specifications

 Product Type: 1-Channel relay module

 Dimensions: 75 mm x 55 mm x 19.3 mm
 Relay colour: Blue
 PCB colour: Blue
 Maximum output of relay: AC250V 10A and Dc30V 10A
 Number of Relays: 1
 Control signal type: TTL level
 Input voltage: 5v
 Compatible with: Arduino, AVR, PIC, ARM, Raspberry Pi etc
 Package contains: 1 piece of 1 channel relay module

C) Transformer

A transformer is electrical device that transfers the energy between two circuits through
electromagnetic induction. A transformer may be used as a safe and efficient voltage converter to
change the ac voltage at its input to a higher or lower voltage at its output. Other uses include
current conversion, isolation with or without changing voltage and impedance conversion. It can
also change the voltage level (lower to higher) and vice versa.

D)Keypad

HEX keypad is a standard device with 16 keys connected in a 4x4 matrix, giving the characters
0-9 A-F. Interfacing of Hex key pad to Atmega32 is essential while designing embedded system
projects which requires character or numeric input or both. For example projects like digital code

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lock, numeric calculator etc. Here we are using this to enter numeric password for turn ON/OFF
the circuit breaker. This can be easily interface with ant kits Microcontroller Development
Board. It is a four pin tactile switch and four mounting holes 3.2mm each

E)LCD Display

The term liquid crystal is used to describe a substance in a state between liquid and solid but
which exhibits the properties of both. Molecules in liquid arrange themselves until they all point
in the same specific direction. This arrangement of molecules enables the medium to flow as a
liquid. Depending on the temperature and particular nature of a substance, liquid crystals can
exist in one of several distinct phases. Liquid crystals in a nematic phase, in which there is no
spatial ordering of the molecules, for example, are used in LCD technology. Here this used to
display the password entered by us to ON/OFF the circuit breakers.

4.2 SOFTWARE DETAILS

4.2.1. Proteus Version 8:

For simulating the circuit this software is been used. Schematic capture in the Proteus Design
Suite is used for both the simulation of designs and as the design phase of a PCB layout project.
The micro-controller simulation in Proteus works by applying either a hex file or a debug file to
the microcontroller part on the schematicHere, the libraries used are:
a. Arduino library (Arduino.LIB and Arduino.IDX)

b. Ultrasonic library (UltrasonicTEP.IDX, UltrasonicTEP.LIB and UltrasonicTEP.HEX)

c. Solar panel library (SolarPanelTEP.IDX and SolarPanelTEP.LIB)

4.2.2 NI Multisim Version 12.0

For simulating the power supply design, Multisim is used. Output of solar panel (12V) is applied
as input to voltage regulator and 5V output is verified at the output of voltage regulator.

4.2.3. Arduino IDE

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All the software programming is written in Arduino Integrated Development Environment (IDE).
Arduino IDE is open-source software which makes it easy to write code and upload it to the
board. It runs on Windows, Mac OS X, and Linux. Interrupts are used in programming to make
system more effective and respond to changes accordingly.
Here, the libraries used are:
a. Ultrasonic library
b. Wire library

4.2.4 Thingspeak
ThingSpeak™ is an IoT analytics platform service that allows you to aggregate, visualize and
analyze live data streams in the cloud. ThingSpeak provides instant visualizations of data posted
by your devices to ThingSpeak. With the ability to execute MATLAB® code in ThingSpeak you
can perform online analysis and processing of the data as it comes in. ThingSpeak is often used
for prototyping and proof of concept IoT systems that require analytics.
ThingSpeak allows you to aggregate, visualize and analyze live data streams in the cloud. Some
of the key capabilities of ThingSpeak include the ability to:

 Easily configure devices to send data to ThingSpeak using popular IoT protocols.
 Visualize your sensor data in real-time.
 Aggregate data on-demand from third-party sources.
 Use the power of MATLAB to make sense of your IoT data.
 Run your IoT analytics automatically based on schedules or events.
 Prototype and build IoT systems without setting up servers or developing web software.

Automatically act on your data and communicate using third-party services like Twilio® or
Twitter®.

4.2.5 Protel
Protel schematic Pcb (printed circuit board) design 1.5 is a great designing software for
electronics and electrical engineers for PCB designing.

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CHAPTER 5
DESIGN& IMPLEMENTATION

5.1 POWER SUPPLY DESIGN

The major blocks of power supply are given below Transformer, Rectifier, Filter, 7805 voltage
regulator .These will provide the regulated power supply to the unit which is first converted into
12V AC. 12V AC is converted into DC using rectifier circuit .Finally the 7805 voltage regulator
provides constant 5V DC supply which will be given to circuit.

Specification:
 For 230V to 12 V unregulated Power supply
 Input voltage : 230 V 50 Hz
 Output voltage: 12 V
 Output current : 2 A
 Maximum ripple : 5%
 Capacitor : 0.033 F
 Transformer:
 Max Vo : 13.7 V
 Vprimary : 230 VAC
 Vsecondary : 10 VAC
 Frequency : 50 Hz
 Power : 27.4 VA
 Diode Bridge :
 V_reverse : 60 V
 Idiode : 4 A
 Fuse : 0.2 A
 For 12 V to 5 V regulated section:
 Voltage regulator chip : LM 7805
 Capacitive filter :
 I/P capacitor : 0.33x10^6 F

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 O/P capacitor : 0.1x10^6 F

 For 12 V to 5 V unregulated section :
 Vomin : 8 V
 Capacitor : 1000x10^6 F
 Vdc FL : 10.5 V
 Vdc NL: 18.5 V
 PIV(peak inverse voltage) : 25 V
 Diode : 1A @ 25 V
 Transformer : 230/15 VAC @ 2A

Calculations of 5 V and 3.3v power supply

BRIDGE RECTIFIER

Rectifier: A single silicon rectifier diode in forward conduction develops a voltage of around
0.7V (but can be up to 2V). In general we allow about 2V -3V drop for the bridge rectifier
configuration.

The voltage at different points in the circuit, based on a 240:12V transformer. Here you can see
the output from the transformer. The output is a sine wave centered around 0 volts. The peak
voltage Vpk is 1.414 times the RMS output - the transformers quoted value.

Thus Bridge rectifier output is

Vdc= ( Vac X 1.414)-1.4.

Here,

Vac=12V

Therefore Vdc= (12 * 1.414)-1.4

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=16.968-1.4

=15.568≈15V

SMOOTHING CAPACITOR

If we assume that your step down transformer reduces the amplitude of 60 Hz sine wave from
220 V to 15 V, and if we assume that your 5 V power supply will need to output at most I_max =
1 A current, then we can start making some calculations. Your smoothing capacitor, which you
will place after the bridge rectifier, will have V_max = 15 V on it, which is the amplitude of your
sine wave. In the image:

Fig No.5.1 Rectifier Output

You see that capacitor discharges during almost the whole period of half-wave rectified wave (in
our case this discharge is caused by the Imax = 1 A load current going into LM7805). The
discharge time of reservoir capacitor in the case of half-wave rectifier is Tdischarge = T = (1/f) =
(1/60 Hz) = 16.6 ms, however, notice that, in our case we have a more sophisticated rectifier
(Diode bridge) which gives a full-wave rectified output. So, the discharge time will be
Tdischarge = T/2 = (1/2*f) = 8.3 ms.

Now, at the beginning of each discharge period our capacitor is charged up to Vmax = 15 V. In
order to prevent our capacitor voltage going below Vmin = 7 V (which is the lowest input
operating point for LM7805 voltage regulator) in the end of the discharge period, our capacitor
value should be chosen with the equation:

C >= (Imax*Tdischarge)/(Vbeforedischarge -Vafterdischarge)

Using the values; Vbeforedischarge = Vmax = 15 V.

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Vafterdischarge = Vmin = 7 V.

Imax = 1 A

Tdischarge = 8.3 ms,

We can calculate that:

Cmin = (1 A)*(8.3 ms)/ (15 V - 7 V) = 1 mF=1000uF.

Calculation of 3.3 V using LM317

The output voltage is selected using two resistors. Normally R1 is chosen to be around
220Ω or 240Ω. The formula for calculating the value of R2 is

Vout = Vref*(1+ (R2/R1))

Or to put it another way

R2=R1 ((V/1.25)-1)

Setting R2 to zero (ground the adjusting pin) will cause the output voltage to drop to 1.25V. R2
may be replaced by a pot to give an adjustable output voltage range.

Here Vout=3.3V, Vref=1.25 and Assuming R1=330E

Then R2=330((3.3/1.25)-1)

=330(1.64)

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=541E.

So the R2 is replaced with POT to adjust the output voltage.

Design Consideration

Design Calculation of power supply

From the solar panel used we will get an output of 12V. However, the microcontroller requires
5V supply input. To get 5V regulated output we use LM7805. Dropout Voltage of LM7805 is
2V, so minimum input voltage required at input of regulator to get 5V output is= Output of
LM7805 + Dropout voltage=5+2=7V. So minimum input voltage is 7V and maximum input
voltage is 35V (ref. datasheet) for which LM7805 gives 5V regulated output.

Regulated power supply 12V/1A: -

Almost all electronic circuits require a DC source for power supply unit may be defined as a
piece of equipment, which converts the alternating waveforms from the power lines (A C supply)
into an essentially direct voltage A rectifier with filter gives out unregulated supply An
unregulated power – supply consists of a transformer, a rectifier, and filter circuit .There are
three reasons why such a simple system is not good enough for same.

1) The first is its poor regulation i.e. the output voltage is for from constant as the load varies.

2) The second is that the D.C output voltage varies with the A.C input directly in many locations
the line voltage for nominal value 230 v may vary as wide a range as 150 v to 270 v and yet it is
necessary that the D.C voltage remains essentially constant.
3) The third is that the D.C voltage varies with temperature particular if semi- conductor
are used.
For any regulated power supply unregulated input voltage should be
Vin=1.5 X Vout. -------------------- (1)

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For output 12V input should be 18V.

1) Transformer
Required o/p voltage will depend upon the Vm rating of transformer
Selected step down transformer of rms voltage rating 0-12V/500ma.
Vin=1.414 x Vrms
Vin=1.414 x 12

Vin=17 Volts.--------------------(2) eqn(2) satisfies eqn(1)

Vdc=2xVm/3.14
Vdc=2x17/3.14
Vdc=10.82V

2) Diode 1N4007

Rectifier diode PIV rating should be greater than Vm rating of transformer and current capacity
should be up to required current.
PIV=2xVm

=2x1.414xVrms =34 Volt.

Pdmax = Avergae current x On state drop Assume average current to be 500ma from diode.
Hence Pdmax =500ma x 0.7 V
Pdmax = 350 mw
Specification of Selected diode: 1N4007
PIV=700V
Iavr=1Amp
Power dissipation =Pdmax=400mWatt

3) Filter Capacitor:

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Filter Capacitor design on the basis of ripple. To have a minimum ripple C should have
maximum value because ripple is inversely proportional to capacitor value. The voltage rating of
capacitor should be greater than Vm rating of transformer. Assumption of ripple will be from 5%
to 10%.

Assume allowed ripple is 10%. Hence o/p voltage may have extreme change from 13.2V to
10.8V means capacitor can charge up to 13.2V (V1) and discharge to 10.8V (V2).

V2=10.8V= √2 x (12-0.7V).Sinwt. 0.7 V considered as on state drop across diode.

Capacitor will discharge up to 10.8 after 90 deg as from the waveform of fullwave rectification.
Hence
Sinə =10.8 / √2 x (12-0.7V)
Sinə =10.8/15.97
Sinə =0.67
Sine inverse of this factor will give us angle 42 deg. 90 deg.=5 msec
Hence total time = 5+2.4 = 7.4msec
 Cap=ΔQ/ ΔV   ΔQ=I x t
=500 ma x 7.4 msec

= 3.7 ma x msec =3700 micro Cap = 3.7mili/2.4 V

=1.54 mf =1540 uf/25V

Hence selected capacitor may be higher than this capacity. 2200uf/25V

4) Three pin voltage regulator.

A voltage regulator is a circuit that supplies a constant voltage regardless of changes in load
current. The 78XX series consists of three terminal positive voltage regulators with seven

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voltage options. These ICs are designed as fixed voltage regulators with adequate heat sinking
can deliver output currents in excess of 1A.
Three-pin regulator 78XX series 7805, --- 7812,---7824

Features of 78xx series:-

1. Output current in excess of 1A.

2. Internal thermal over load protection.
3. No external component requires.
4. Output transistor safe area protection.
5. Internal short circuit current limit.
6. Available in plastic to 202 package

Absolute maximum ratings of 78xx series:-

1. Max. Input Voltage : 37V.
2. Operating temp. Range : - 0 C-100
3. Max junction Temp. :- - +1240C
4. Storage temp. Range :- - 650C to +1500C
5.Lead temp. (Soldering 10- second) :- - +2300C

5)Additional Filter capacitor :

10uf–100uf additional filter capacitor will improve the load regulation characteristics. It is
connected at the output.

6) Decoupling capacitor:
0.01uf To 0.1uf capacitor will remove the high frequency noise superimposed at output.

7) LED for indication:-

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At the output of power supply led in series with 1.5k for 12V is connected to indicate the on state
of power supply.
I forward led= 2V
I forward led=10ma.
V=Is x Rs + V forward
led 12V= 10 ma x Rs +
V Rs= 12 V-2 V/
(10ma) Rs= 1K
For 12V Rs is up to 1K to 1.5Kohm.

Need of heat sink

As we increase Vin for LM7805 power dissipation also increases. For LM7805, maximum
power dissipation is 15W (ref. datasheet). In our design, power dissipation is =
Vdc*Io=12*0.3=3.6W.
2.7W<15W. So it does not need heat sink.

Bulk Decoupling capacitor

We connected 100 uF at output of regulator as a decoupling capacitor. It is optional. When
devices connected to the 5V supply heavy current from power supply, output of regulator may
fall down and become unstable. In such cases 100uF provides power to the devices by
discharging itself to maintain 5V output constant. Value of decoupling capacitor may be >10 uF.

5.2 PCB DESIGN

PCB Designing
Printed circuit boards may be covered in two topics namely. PCB means printed circuit board
PCB is one of the most important elements in any electronic system. They accomplish the
interconnection the between component mounte. PCB consist of conductive circuit pattern which
is applied to one or both sided of an insulating base copper is most widely used for conductor

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material. Aluminum nickel, silver, brass is used for same special application. The thickness of
conducting material depends upon the current carrying capacity of circuit. Thus a thicker
conductor layer will have mare current carrying capacity once the PCB is manufactured the
current carrying capacity is depends on which of conductor track.

Types of PCB
 Single sided PCB.
 Double sided PCB.

Single Sided PCB

This type of PCB consists of a natural coil of a copper on only one side of the base material. This
type of PCB frequently used when the manufacturing cost has to be kept at minimum.

Double Sided PCB

Double sided PCB is used when there is more number of jumpers. This type of PCB has copper
fail on both side of base material. The double-sided PCB’s are used 2when insulation of PCB is
very complicated i.e. if jumpers are more in number and when it is difficult to fabricants the PCB
ON a single sided PCB.

PCB Design Steps:

Preparations are
 Layout planning
 Artwork drawing
 Artwork transforming
 Painting
 Etching
 Drilling
 Soldering

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Manufacturing processes of PCB:

The conductor pattern which is on the master film is transferred on copper clad laminate by two
methods.
 Photo resist printing
 Screen printing.

Photo resist printing Photopolymer resist is a light sensitive organic material like KPR (Kodak
Photo resist) which is applied to the board as a thin film, The photo resist when exposed to
ultraviolet light hardens or polymerizes. Once it is polymerized, it becomes insoluble to
certain chemical solvents known as developers. The developer dissolves the portion which is
masked or which is not exposed to light. Thus the pattern that is to be drawn
on PCB is derived from the artwork which is photographic process. This is transferred to a
master film on 1:1 scale. This can be reduced to any small size thus miniaturization is possible.
The pattern is transferred to a mask. This mask is kept on PCB. The whole process is known as
Image transfer. The unpolymerized or masked portion is washed away in developer leaving
wanted copper pattern on board KPR or photo resist is then removed. This technique is similar to
the one used in printing industry. The copper foil is covered with printing ink where the
conducting paths are going to be. The screen which is used for pattern is of either stainless steel
or polyester mesh which is dimensionally accurate and fine mesh. The open meshes of screen
correspond to the pattern. PCB is placed under the screen. Printing ink is placed at one end of the
screen, and by means of a rubber squeegee it is pushed through open meshes, Printed circuit
board is then removed for drying. After drying board is washed in ferric chloride which acts as
etchant. Etching is chemical process by which unwanted copper is removed. The portion which
is covered by ink is not removed, that is the pattern remains intact. Later ink stripping is done
with trichloroethylene.
 Protection of copper tracks Copper when exposed to atmosphere for a long time gets
tarnished and problems are created while soldering. The tracks can be protected by applying
lacquer or varnish properties, the thickness of these coatings. Copper is also protected by plating.
There are three methods of plating 1. Immersion plating 2. Electro less plating 3. Electroplating
(1) Immersion plating utilizes tin and its alloys and gold. It is done by chemical replacement
from coating material salt solution. This method is simple and less costly.

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(2) In electro less copper plating electric current is not used instead a chemical reducing agent is
used which supplies electrons for reaction in which copper is reduced from its ionic state
(3)In electroplating a. d. c current is passed between two electrodes, and a thin coating is
deposited on 2 2cathode when immersed in electrolyte.

Function The printed circuit board usually serves there distinct functions are as follows:

 It provides mechanical support for the component mounted on it.

 It provides necessary electrical interconnections.
 It acts as a heat sink i.e. it provides a conduction path leading to removal of most of the heat
generate in the circuit.

Advantage of PCB
Over the conventional wire method:
 PCB’s have controllable and predicable electrical mechanical properties.
 Rapid production is possible.
 Time is saved since it avoids wiring connections production to another  Weight is reduced.
 Soldering is done in one operation instead of individual connection between component and
wires.
 Cost is less.

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CHAPTER 6
RESULTS AND DISCUSSION

6.1 MANUFACTURING STEPS

There are various steps involved in manufacturing and production of the system hardware.
Some of the steps are listed below. A well-executed design and development cycle for an
electronic product requires travel through many stages before arriving at a successful conclusion.
Here are the stages that we have determined are needed to create a well-designed electronic
product.

• Concept
The concept of plant monitoring emerged with increase in the number of conditions and mishaps
around the world and a greater need of safety measures.

• Research
The stage at which the product concept is utilized to fuel research that includes identifying the
technology, methods, and vendors involved in producing the product. This stage of research must
result in a detailed design specification that is used to cost the design process that follows as well
as the estimated manufactured cost of the product.

• Circuit Design
The stage where a schematic diagram is created (usually via computer drafting software) and a
preliminary parts list is created for costing and prototyping the product. The circuit design of the
system was developed in the proteus software and it was helpful in correcting connection
errors.It also gave an estimate of the hardware needed. It defined the cost parameters, feasibility
and an estimate of time needed to complete
the project.

Packaging and Printed Circuit Design

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This is the stage where the device under design gets a suitable enclosure designed or selected.
This enclosure selection as well as connectors, controls, and displays must all be resolved before
the printed circuit layout commences. The first step in designing a printed circuits the
mechanical pattern or outline of the board assembly itself.

• The major steps in this process are:

A package (housing) is selected or designed. If designed, the mechanical drawing must be
produced of the assembly. If selected, this drawing will be supplied by the
manufacturer.Nomenclature and graphics for the enclosure will be designed. This may be applied
in the form of labels, overlays, silkscreens, or a combination. The printed circuit layout
commences and resolves the requirements of the circuit diagram usage of electronic components
with the form factor demanded by the packaging design process.
The printed circuit artwork is processed on film and used by a manufacturer to etch printed
circuit boards for the board assembler. A silkscreen of part locations to assist in the assembly
process is normally applied on the printed circuit card by the manufacturer.

The PCB designing involved steps into converting the circuit designing into a board by making
connections compact. It also involved taking into consideration the rules of PCB designing and
optimization of space and resources.

• Prototyping or Trial Production

Sometimes prototypes are built before stage 4 (packaging and printed circuit layout) but the
speed and cost advantages of computer aided design are making this more uncommon. A hand-
wired prototype of all or a portion of the circuit may be required for the design process.

• The prototyping process involved development of a trial product for testing purposes. It was
done to save cost and minimize error probability after actual production.

• Design Review

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The stage where the prototype and initial units are evaluated for function, appearance, build-cost,
and possible enhancements. This process should result in minor changes but is a must to insure
compliance with the original goals. The design review appeared to be positive as all the units
worked as expected. Some problems were faced as the slaves were resetting after every two
seconds causing hindrance in the operation. It was caused because of excessive heat in the power
supply capacitors. An additional heat sink was attached to the regulator IC to avoid the problem.

• Manufacturing Setup including Test Setup

The stage is where the necessary test procedures and apparatus, fixtures if necessary, and
detailed assembly instruction and documents are put in place in order to yield quality, tested
products when quantity production takes place. In this case, mass production was not an
objective hence testing methods were used to test the system for durability and safety.

• Testing methods
PCB Cold test: The first step was to carry out the visual inspection of the PCB. This means to
check any short or cut in the tracks in aspects the tracks on PCB find any missing pads if
anywhere found on it we did mechanical repair of the same

The second step involved the continuity testing. This means to check that the current is flowing
through all the tracks thirdly testing soldier of socket crystal & rest circuitry.

Testing for LCD: First of adjust the contrast voltage (VC) of the LCD such that the visibility of
the displayed information is proper other to make a clear visibility the pot was further adjusted at
a last measure. Then initialize the LCD then write a small program. To display character on
LCD. When the character was not displayed we checked again for LCD connections and
repeated the procedure after reinitializing it.

• Documentation
The phase where circuit diagrams, parts lists, master printed circuit artwork, parts sources,
software source code and documentation, mechanical drawings, assembly drawings, and all other
items included as part of a project's deliverables are provided.

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This package should be sufficient so as to make the product producible by any qualified source,
not just the parties involved in the design. In the context this system the project report, a
reference CD, compilation of data sheets and arranging them in proper order consisted of the
documentation work.

• Follow-up
The sponsors of the project released the system for relevance testing in the network and got a
positive response. There were some suggestions during the follow up of the system performance
which are included in the project future scope. The follow up came out to be a successful
exercise as it gave out many suggestions and improvement space for the system.

6.2 ADVANTAGES

• It makes the process simpler.

• It makes our work more cordiblle.
• It makes us to do many task on a single go.
• It can lead to smart system development ,hence the devices can response to any change in
the stimulus automatically

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CHAPTER 7
CONCLUSION AND FUTURE SCOPE
7.1 CONCLUSION
It can work on given known password and it gives no scope of password stealing.It
ensures the line man safety and it reduces load demand in the distribution side.There is also a
provision of changing the password.

7.2 FUTURE SCOPE

The system can be easily connected to the personal computer for further control.
Other than the speaker sounds, all the lights are made to turned on if password entered is
wrong for three times and also a hidden camera is used to record the faces who trespassed.
We can use this system as an attendance register for the students to enter a class room with
their respective password.

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REFERENCES
[1] Veena, “Electric line man safety system with OTP based circuit breaker”, SR Engineering
College, Volume:2, May 2015

[2] Muhaad Ali Mazidi and Janice Gillisllispie Mazid, “The Microcontroller and embedded
system”, Person Education,2nd edition,Issue:1999

[3] Dr.Neelam Rup, Prakash, “International Journal of Engineering Trends and Technology”,
(IJETT) ,Volume 13, page:261,Issue:3 – Jul 2014.

[4] Mark Halpin: “National Code Committee”, Volume40,page:228,Issue:2002

[5] Deepak Sharma & Major Sing Goraga: “International Journal Of Current Engineering And
Scientific Research (IJCESR)” Volume2,issue-May 2015

[6] Athira P Nair: “electric line man safety system with otp based circuit breaker” BTC College
of Engineerimg, Kerala, ,Volume :04,issue: April, 2015

[7] VINCENTB DEL TORO:“Electrical Engineering Fundamantals”,Issue:1-Jan 1986

[8] John M.Osepchuk: “IEEE Engineering in Medicine and Biology Volume15(1),Page:116-

120,Issue:June 1996.

[9] David J. Marne, “National Electrical Safety Code” issue:1997

[10] Mohammad Tasdighi: “Inductive FCL's impact on circuit breaker's interruption condition
during short-line faults” North American Power Symposium (NAPS), Issue: 22-24 Sept2013

[11] T.Matsumura, T. Uchii and Y. Yokomiz:"Development of Flux-Lock Type Fault Current

Limiter with High-Tc Superconducting Element", IEEE Transactions on Applied
Superconductivity, by “: Vol. 7, No. 2,Issue:June 1997

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