INTELIGENT RAILWAY SYSTEM

VisualizeGate Control andTrack Switching
1
INDEX
Ch.No. Chapter Name Page No.
1 Introduction 01
2 Specification 03
3 Design Procedure 08
4 Hardware
 Principle of Operation 09
 Hardware Details 10
 Block Diagram 13
 Circuit Diagram 14
5 Software
 Algorithm 17
 Flowchart 19
 Software Listing 23
6 Circuit Preparation(PCB making &
Trouble Shooting)
66
7 Advantages, Disadvantages & Application 73
8 Future Scope 74
9 Cost Sheet 75
10 Conclusion 77
11 References 80
12 Datasheet 82
13 Photograph 102

2
INTRODUCTION

3
INTRODUCTION
Indian railway has the 2nd largest railway network in the world. As the 21st century is
moving ahead, the Indian railway system is also moving ahead in terms of technology. But then
also, till today our system have not been developed to such a level that it can able to avoid the
train accidents in India. In the last 2 years, total 46 major accidents occurred in which more than
9000 Indians and over 859 foreigners lost their lives.
Most of the train accidents in India occurs due to the miscommunication, bad weather
conditions (fog), human errors, non-update information about the train. Due to these reasons
many Indian people lost their life’s and also the foreigners. Today railway is one of the main
source for the transportation of people as well as goods in India. In train accidents almost 19% of
the total goods get wasted, it may be coal, steel, iron, petroleum, oil etc.
In today’s competitive world lot of things works on automation, this reduces use of
human resources to a great extent and because of this time and money are also saved. Which is
economically profitable in today’s life. In this system more work is done with less investment,
proper management and discipline is maintained.
As we want to solve the problems of accidental damage of railway system, to maximize
the people security, and to get the more information about railway position. We found the best
solution for that are “VISUALIZE GATE CONTROL AND TRACK SWITCHING” in
Railway system.
For this project we design a circuit which gives whole information about the Railway
system. In this project we use the IR sensors and it is placed before and after the Railway
Crossing so when any Train enters the area of Railway Crossing at that time gate is automatically
closed.
If two trains arrived on same track and cuts IR sensors in opposite directions the red
signals is given to both train to avoid the accident. If we want to switch the train on different
tracks then we can switch it using master control.

4
SPECIFICATION

5
Specification
IR Sensor
This is a simple yet effective IR proximity sensor built around the TSOP 1738 module.
The TSOP module is commonly found at the receiving end of an IR remote control system; e.g.,
in TVs, CD players etc. These modules require the incoming data to be modulated at a particular
frequency and would ignore any other IR signals. It is also immune to ambient IR light, so one
can easily use these sensors outdoors or under heavily lit conditions.
Such modules are available for different carrier frequencies from 32 kHz to 42 kHz. In
this particular proximity sensor, we will be generating a constant stream of square wave signal
using IC555 centered at 38 kHz and would use it to drive an IR led. So whenever this signal
bounces off the obstacles, the receiver would detect it and change its output. Since the TSOP

6
1738 module works in the active-low configuration, its output would normally remain high and
would go low when it detects the signal (the obstacle).
Microcontroller 89S52
 Compatible with MCS-51® Products
 8K Bytes of In-System Programmable (ISP) Flash Memory
 4.0V to 5.5V Operating Range
 Fully Static Operation: 0 Hz to 33 MHz
 Three-level Program Memory Lock
 256 x 8-bit Internal RAM
 32 Programmable I/O Lines
 Three 16-bit Timer/Counters
 Eight Interrupt Sources
 Full Duplex UART Serial Channel
 Low-power Idle and Power-down Modes
 Interrupt Recovery from Power-down Mode
 Watchdog Timer
 Dual Data Pointer
 Power-off Flag
Push –Pull Four Channel Driver with Diodes (L293D)
 600mA output current capability per channel
 1.2A peak output current per channel (non repetitive)
 Enable Facility
 Over Temperature Protection
 Logical ”0” input voltage up to 1.5 V to 5V
 High Noise Immunity
 Internal Clamp Diodes

7
MAX232
 Operate from Single +5V Power Supply
 +5V and +12V (MAX231/MAX239)
 Low-Power Receive Mode in Shutdown (MAX223/MAX242)
 Meet All EIA/TIA-232E and V.28 Specifications
 Multiple Drivers and Receivers
 3-State Driver and Receiver Outputs
 Open-Line Detection (MAX243)
Voltage Regulator IC 7805
 Output current in excess of 1A
 Internal thermal overload protection
 No external components required
 Output transistor safe area protection
 Internal short circuit current limit
 Available in the aluminum TO-3 package

8
DESIGN
PROCEDURE

9
DESIGN PROCEDURE
a) HARDWARE:
• Principle of Operation:
1. We are using the Infrared sensor (IR) pairs for detecting the train. As the train
obstructs IR signals, IR will send the received signals to the controller indicating that
the train is arrived. When the train obstructs the 1st IR sensor, it will turn ON buzzer
for particular period of time and then the gate will automatically get closed.
2. The buzzer is basically used as a warning alert for people near the railway gate.
3. We can calculate the speed of train using distance between two IR sensors (fixed) and
the time difference required by train to obstruct the 2 IR sensors.
4. When the train is arriving from 1 side, the signal on the same track will indicate red
signal to opposite direction.
5. If we want to route the train on different tracks then we can switch the tracks using
master controller (PC).
6. These all are represented on computer (master controller) and provide master control
to operator. [I.e. gate status, signal status, tracks switching, speed measurement,
position of train.]
7. IR sensors are also used for the automatic railway gate control which is performed by
using the outputs of the IR sensors which are given to the DC motor used for the gate.
8. The status of the railway gate is represented on the PC and it is also controlled by the
master controller (PC).

10
• HARDWARE DETAILS
1. MICROCONTROLLER 89S52
We are using ATMELS AT89c/s51 microcontroller. The controller executes instructions as
per the clock cycles; this clock is generated using a crystal which is connected to the XTAL1 &
XTAL2 pin of the microcontroller, the two capacitors C1 & C2 are connected between the two
XTAL pins & the ground. They are required for the crystal to oscillate.
A Power ON reset circuit is connected to the RESET pin of the microcontroller, the controller
must be reset properly whenever is power is turned on, which is done by applying a Vcc to the
reset pin & for normal operation of the controller the pin should be pulled low. So an RC (R1,
C3) circuit is connected to the RST (9) pin of the microcontroller. Whenever the power is turned
ON the Capacitor is fully charged & the RST pin gets 5 v. Then the capacitor slowly discharges
through the resistor & is then pulled to ground.
Microcontrollers Port 0 does not have an Internal Pull Up resistor so we need external Pull Up
resistors on port 0. For which we use 9-Pin SIP resistor which are basically eight resistors with
one end common.
Components: XTAL=11.0592 MHz, C1=C2= 33pf, R1=10kΩ, C=10uf
2. TSOP 1738basedproximity sensor
This is a simple yet effective IR proximity sensor built around the TSOP 1738 module.
The TSOP module is commonly found at the receiving end of an IR remote control system;
e.g., in TVs, CD players etc. These modules require the incoming data to be modulated at a
particular frequency and would ignore any other IR signals. It is also immune to ambient IR
light, so one can easily use these sensors outdoors or under heavily lit conditions.
Such modules are available for different carrier frequencies from 32 kHz to 42 kHz. In
this particular proximity sensor, we will be generating a constant stream of square wave signal

11
using IC555 centered at 38 kHz and would use it to drive an IR led. So whenever this signal
bounces off the obstacles, the receiver would detect it and change its output.
1. POWER SUPPLY SECTION
We require 5 volts for microcontroller, LCD, EEPROM & approximately 12 volts for the
Relay. These voltages are generated from 230v line voltage. Initially A step down Transformer is
used to step down 230volts to 9olts, so a 0-9; 500ma step down transformer is used. The output
of the step down transformer is also AC, we convert this AC voltage into DC by using a Full
wave bridge rectifier consisting of Diodes D1, D2, D3 & D4. During the positive half cycle
diodes D1 & D4 conduct whereas in the negative half cycle diodes D2 & D3 conduct thus the
diodes keep switching the transformer connections so we get positive half cycles in the output.
Even though half wave & full wave rectifier give DC output, none of them provides a constant
output voltage. For this we require to smoothen the waveform received from the rectifier. This
can be done by using a capacitor at the output of the rectifier this capacitor is also called as
“FILTER CAPACITOR “or “SMOOTHING CAPACITOR” or “RESERVOIR CAPACITOR”.
Even after using this capacitor a small amount of ripple will remain.
We place the capacitor at the output of the rectifier the capacitor will charge to the peak
voltage during each half cycle & then will discharge its stored
energy slowly through the load while the rectified voltage drops to
zero, thus trying to keep the voltage as constant as possible. If we
go on increasing the value of the filter capacitor then the Ripple
will decrease. But then the costing will increase. The value of the

12
Filter capacitor depends on the current consumed by the circuit, the frequency of the waveform
& the accepted ripple.
C=VrF/I
Where,
Vr= accepted ripple voltage.( should not be more than 10% of the voltage)
I= current consumed by the circuit in Amperes.
F= frequency of the waveform.
After filtering the rectifier output the signal is given to a voltage regulator. The maximum input
voltage that can be applied at the input is 35V.Normally there is a 2-3 Volts drop across the
regulator so the input voltage should be at least 2-3 Volts higher than the output voltage. If the
input voltage gets below the Vmin of the regulator due to the ripple voltage or due to any other
reason the voltage regulator will not be able to produce the correct regulated voltage. We require
5v output so we use IC 7805 where 78 indicates that it’s a positive series & the 05 indicates the
output voltage.
Another capacitor C4 is used after the voltage regulator, this is used to remove any ripples or
noise generated in the Vcc. D7 is an LED used to indicate the Power Status
Components: Transformer: Step Down 0-9; 500ma, Diodes: 1n4007 (D1, D2, D3
and D4), Capacitor (c11) = 1000uf, Voltage Regulator= 7805, Capacitor C4 =
100uf, Resistor R10 =2.2KΩ. LED1 = 3mm Transparent white LED.

13
BLOCK DIAGRAM:-
Micro
controller
8
9
S
5
2
MAX 232
DC MOTOR
DRIVER
(L293D)
PC
LED
DC motor

14
CIRCUIT DIAGRAM:-
IR SENSORS

15
LAYOUT:-

16
COMPONENT PLACEMENT & DESIGN :-

17
b) SOFTWARE
 ALGORITHM
Gate Controlling
1) start
2) initialize all i/o pins.
3) Open the gate
4) wait for sensor to be cut
5) send the sensor cut location to PC
5) Close the gate
6) wait for other sensor to be cut
7) send sensor cut location to PC
8) Open the gate
9) go to 4
10) Stop
Track Switching
1) Start
2) Initialize all I/O pins.
3) Wait for data from PC
4) If data received = cmd_track1_side1 then move track1 to side 1 and go to 3

18
8) go to 3
9) stop
Anti-Collision System
1) Start
2) Initialize all i/o pins
3) show green led on both sides
4) wait for sensor to be cut
5) Show red led on other side
6) wait for second sensor to be cut
7) go to 3
8) stop

19
FLOWCHART

20
Gate Controlling
START
Initialize all I/O pins.
GATE OPEN
Send the Signal to
the PC
GATE CLOSE
Check the First
IR Sensor Cut
or Not
Check the
Second IR Sensor
Cut or Not

21
Track Switching
START
Wait For Data from
PC
If Data
Received
Cmd_track1_side1 move to track1 to side 1
STOP

22
Anti-Collision System
START
Turn ON Green LED
on both Sides
Check the First
IR Sensor Cut
or Not
Turn ON RED LED
Check the
Second IR Sensor
Cut or Not
Turn OFF RED LED
& Turn ON Green
LED

23
Software Listing
A] Assembly language programming
A51 MACRO ASSEMBLER MAIN
MACRO ASSEMBLER A51 V8.01
OBJECT MODULE PLACED IN main.OBJ
ASSEMBLER INVOKEDBY: C:KeilC51BINA51.EXEmain.asmSET(SMALL) DEBUG EP
LOC OBJ LINE SOURCE
1 ;$include (ini.inc)
0093 +1 2 SENSOR1 BIT p1.3 ;for gate
0092 +1 3 SENSOR2 BIT p1.2 ;for gate
0091 +1 4 gate_close_sensor bit P1.1
0090 +1 5 tracksw_fb1 bit P1.0
0096 +1 6 tracksw_fb2 bit P1.6
0094 +1 7 SENSOR3 BIT p1.4 ;forspeedsame tra
ck
0095 +1 8 SENSOR4 BIT p1.5 ;forsame track

24
+1 9
00B7 +1 10 led_red bit P3.7
00B6 +1 11 led_red1 bit P3.6
00B5 +1 12 led_green bit P3.5
00B4 +1 13 led_green1 bit P3.4
+1 14
+1 15
+1 16
+1 17
0083 +1 18 en1 bit P0.3 ;track swit
ch 2
0084 +1 19 in1a bit P0.4
0085 +1 20 in1b bit P0.5
+1 21
0080 +1 22 en2 bit P0.0 ;track swit
ch 1
0081 +1 23 in2a bit P0.1
0082 +1 24 in2b bit P0.2
+1 25
00A5 +1 26 en3 bit P2.5 ;gate contr
ol
00A3 +1 27 in3a bit P2.3
00A4 +1 28 in3b bit P2.4
+1 29
00A2 +1 30 en4 bit P2.2

25
00A1 +1 31 in4a bit P2.1
00A0 +1 32 in4b bit P2.0
+1 33
+1 34
+1 35
00A6 +1 36 buzzer bit P2.6
+1 37
+1 38
+1 39
+1 40
+1 41
+1 42
+1 43
+1 44
+1 45
+1 46
+1 47
+1 48
0000 +1 49 GATE_CLOSE_F BIT 00H
0001 +1 50 track1_side1_f bit 01h
0002 +1 51 track2_side1_f bit 02h
+1 52
+1 53
+1 54

26
0030 +1 55 delay0 equ 30h
0031 +1 56 delay1 equ 31h
0032 +1 57 DELAY2 EQU 32H
0033 +1 58 sensor_ram equ 33h
0034 +1 59 sametrack_ram equ 34h
+1 60
+1 61
0031 +1 62 s_location1 data '1'
0035 +1 66 s_gate_open data '5'
0036 +1 67 s_gate_close data '6'
0037 +1 68 s_track1_side1 data '7'
+1 72
+1 73
0041 +1 74 cmd_track1_side1 data 'A'
0042 +1 75 cmd_track1_side2 data 'B'
0043 +1 76 cmd_track2_side1 data 'C'
0044 +1 77 cmd_track2_side2 data 'D'

27
0045 +1 78 cmd_gate_open data 'E'
0046 +1 79 cmd_gate_close data 'F'
80
0000 81 org 0000h
0000 758160 82 MOV SP,#60H
0003 11E4 83 call stop
0005 C2A6 84 clr buzzer
0007 C2B4 85 clr led_green1
0009 C2B5 86 clr led_green
000B 1144 87 call delay
000D 1144 88 call delay
000F 1144 89 call delay
0011 11F9 90 call baudrate
0013 7448 91 mova,#'H'
0015 3105 92 call send
0017 7469 93 mova,#'i'
0019 3105 94 call send
001B D2A6 95 setbbuzzer
96
001D 11B4 97 call GATE_close
001F 11CE 98 call gate_open
0021 753300 99 mov sensor_ram,#00h
0024 753400 100 mov sametrack_ram,#00h
0027 1144 101 call delay
0029 31C9 102 call track1_side1

28
002B 1144 103 call delay
002D 31EC 104 call track2_side1
105 ; call receive
106 ;call send
107
002F 108 loop:
002F 115A 109 call check_gate
0031 315A 110 call check_same_track
0033 312E 111 CALL check_serial
0035 80F8 112 JMP LOOP
113
0037 114 Ldelay:
0037 7530FF 115 movdelay0,#0ffh
003A 116 l1_Ldelay:
003A 7531FF 117 movdelay1,#0ffh
003D 118 l2_Ldelay:
119 ; MOV DELAY2,#1
120 ; DJNZDELAY2,$

29
003D D531FD 121 djnzdelay1,l2_Ldelay
0040 D530F7 122 djnzdelay0,l1_Ldelay
0043 22 123 ret
124
125
0044 126 delay:
0047 128 l1_delay:
004A 130 l2_delay:
004A D531FD 131 djnzdelay1,l2_delay
004D D530F7 132 djnzdelay0,l1_delay
0050 22 133 ret
134
0051 135 sdelay:
0051 7F00 136 mov r7,#00h
0053 137 sl1_delay:
0053 7E01 138 movr6,#01h
0055 DEFE 139 djnzr6,$
0057 DFFA 140 djnzr7,sl1_delay
0059 22 141 ret
142 ;$include (gate_control.inc)
005A +1 143 check_gate:

30
005A 1161 +1 144 call check_sensor1
005C 118A +1 145 call check_sensor2
005E 22 +1 146 ret
+1 147
+1 148
+1 149
005F +1 150 R1_check_sensor1:
+1 151 ;NOOBSTACLE
005F D3 +1 152 SETB C
0060 22 +1 153 RET
+1 154
0061 +1 155 check_sensor1:
0061 3093FB +1 156 jnb SENSOR1,R1_check_sensor1
0064 7F30 +1 157 mov r7,#30h
0066 +1 158 deb1_loop:
0066 3093F8 +1 159 jnbSENSOR1,check_sensor1
0069 DFFB +1 160 djnzr7,deb1_loop
+1 161
006B 7431 +1 162 mova,#s_location1
006D 3105 +1 163 call send
+1 164
006F 2093FD +1 165 jbsensor1,$
+1 166
0072 E533 +1 167 mova,sensor_ram
0074 B40007 +1 168 cjne a,#00h,c1_check_sensor1

31
0077 753301 +1 169 mov sensor_ram,#01h
007A C3 +1 170 CLR C
007B 11B4 +1 171 CALL GATE_CLOSE
+1 172 ; mova,#'2'
+1 173 ; call send
007D 22 +1 174 RET
+1 175
+1 176
007E +1 177 c1_check_sensor1:
007E B40206 +1 178 cjne a,#02h,c2_check_sensor1
0081 11CE +1 179 call gate_open
0083 753300 +1 180 mov sensor_ram,#00h
0086 22 +1 181 ret
+1 182
0087 +1 183 c2_check_sensor1:
0087 22 +1 184 ret
+1 185
+1 186

32
+1 187 ;**************************************
+1 188 ;**************************************
+1 189 ;**************************************
0088 +1 190 R1_check_sensor2:
0088 D3 +1 191 SETB C
0089 22 +1 192 RET
+1 193
+1 194
008A +1 195 check_sensor2:
008A 3092FB +1 196 jnb SENSOR2,R1_check_sensor2
008D 7F30 +1 197 movr7,#30h
008F +1 198 deb2_loop:
008F 3092F8 +1 199 jnbSENSOR2,check_sensor2
0092 DFFB +1 200 djnzr7,deb2_loop
0094 2092FD +1 201 jb sensor2,$
+1 202
0097 7432 +1 203 mov a,#s_location2
0099 3105 +1 204 call send
009B 2092FD +1 205 jb sensor2,$
+1 206
009E E533 +1 207 mova,sensor_ram
00A0 B40007 +1 208 cjne a,#00h,c1_check_sensor2
00A3 753302 +1 209 mov sensor_ram,#02h

33
00A6 C3 +1 210 CLR C
00A7 11B4 +1 211 CALL GATE_CLOSE
+1 212 ; mova,#'3'
+1 213 ; call send
00A9 22 +1 214 RET
+1 215
+1 216
00AA +1 217 c1_check_sensor2:
00AA B40106 +1 218 cjne a,#01h,c2_check_sensor2
00AD 11CE +1 219 call gate_open
+1 220 ; mova,#'4'
+1 221 ; call send
00AF 753300 +1 222 movsensor_ram,#00h
00B2 22 +1 223 ret
+1 224
00B3 +1 225 c2_check_sensor2:
00B3 22 +1 226 ret
+1 227
+1 228
+1 229
;***********************************************************************
+1 230
;***********************************************************************
+1 231
;***********************************************************************
+1 232
;***********************************************************************

34
+1 233
;***********************************************************************
+1 234
;***********************************************************************
+1 235
;***********************************************************************
+1 236
;***********************************************************************
+1 237
+1 238
00B4 +1 239 GATE_CLOSE:
00B4 C2A6 +1 240 CLR buzzer
00B6 309104 +1 241 jnbgate_close_sensor,r1_GATE_CLOSE
+1 242 ; jbgate_close_f,r1_GATE_CLOSE
00B9 11EB +1 243 call forward
+1 244 ; call Ldelay
00BB 80F7 +1 245 jmpGATE_CLOSE
+1 246
00BD +1 247 r1_GATE_CLOSE:
00BD 11E4 +1 248 call stop
00BF D200 +1 249 setb gate_close_f
00C1 7436 +1 250 mova,#s_gate_close
00C3 3105 +1 251 call send
00C5 D2A6 +1 252 SETB bUZZER

35
00C7 22 +1 253 ret
+1 254
+1 255
00C8 +1 256 r1_GATE_open:
00C8 7436 +1 257 mova,#s_gate_close
00CA 3105 +1 258 call send
00CC C3 +1 259 clr c
00CD 22 +1 260 ret
+1 261
+1 262
00CE +1 263 GATE_open:
00CE 3000F7 +1 264 jnb gate_close_f,r1_GATE_open
00D1 11F2 +1 265 call reverse
00D3 1137 +1 266 call Ldelay
00D5 1137 +1 267 call Ldelay
00D7 1137 +1 268 call Ldelay
00D9 1137 +1 269 call Ldelay
00DB 11E4 +1 270 call stop
00DD C200 +1 271 clr gate_close_f
00DF 7435 +1 272 mova,#s_gate_open
00E1 3105 +1 273 call send
00E3 22 +1 274 ret
+1 275

36
+1 276
+1 277
+1 278
00E4 +1 279 stop:
00E4 C2A5 +1 280 clr en3
00E6 C2A3 +1 281 clr in3a
00E8 C2A4 +1 282 clr in3b
00EA 22 +1 283 ret
+1 284
00EB +1 285 forward:
00EB D2A5 +1 286 setben3
00ED D2A3 +1 287 setbin3a
00EF C2A4 +1 288 clr in3b
00F1 22 +1 289 ret
+1 290
+1 291
00F2 +1 292 reverse:
00F2 D2A5 +1 293 setben3
00F4 C2A3 +1 294 clr in3a
00F6 D2A4 +1 295 setbin3b
00F8 22 +1 296 ret
+1 297
+1 298
;***********************************************************************
+1 299
;***********************************************************************

37
+1 300
;***********************************************************************
+1 301
;***********************************************************************
302
303 ;$include (serial.inc)
+1 304
;**********************************************************************************
+1 305
;**********************************************************************************
+1 306
;**********************************************************************************
00F9 +1 307 baudrate:
00F9 759850 +1 308 movscon,#50h
00FC 758921 +1 309 mov tmod,#21h ;Timer1 in Auto-reloadmode , TIMER 0 FOR
GETTING COUNT
FROM SUB PLC
00FF 758DFD +1 310 movth1,#0fDh ;Reloadvalue for4800 baud@ 11.059 Mhz
0102 D28E +1 311 setbtcon.6 ;Turn on timer1
0104 22 +1 312 ret
+1 313
;**********************************************************************************
+1 314
;**********************************************************************************
+1 315
;**********************************************************************************
+1 316
;**********************************************************************************
0105 +1 317 send:

38
0105 F599 +1 318 mov sbuf,a
0107 +1 319 lsend1:
0107 3099FD +1 320 jnb scon.1,lsend1
010A C299 +1 321 clr scon.1
010C 22 +1 322 ret
+1 323
;**********************************************************************************
+1 324
;**********************************************************************************
+1 325
+1 326
;**********************************************************************************
+1 327
;**********************************************************************************
010D +1 328 receive:
010D 3098FD +1 329 jnbscon.0,receive
0110 C298 +1 330 clr scon.0
0112 E599 +1 331 mova,sbuf
0114 22 +1 332 ret
+1 333
;**********************************************************************************
+1 334
;**********************************************************************************
+1 335
+1 336
;**********************************************************************************

39
+1 337
;**********************************************************************************
0115 +1 338 newline:
0115 740A +1 339 mov a,#10
0117 3105 +1 340 call send
0119 740D +1 341 mova,#13
011B 3105 +1 342 call send
011D 22 +1 343 ret
+1 344
;**********************************************************************************
+1 345
;**********************************************************************************
011E +1 346 send_dptr_string:
011E E4 +1 347 clr a
011F 93 +1 348 movc a,@a+dptr
0120 7003 +1 349 jnz c1_send_dptr_string
0122 02012B +1 350 ljmpr1_send_dptr_string
+1 351
0125 +1 352 c1_send_dptr_string:
0125 3105 +1 353 call send
0127 A3 +1 354 inc dptr
0128 02011E +1 355 ljmpsend_dptr_string
012B +1 356 r1_send_dptr_string:
012B 22 +1 357 ret
+1 358
;**********************************************************************************
+1 359
;**********************************************************************************

40
+1 360
;**********************************************************************************
+1 361
;**********************************************************************************
012C +1 362 r1_check_serial:
012C C3 +1 363 clr c
012D 22 +1 364 ret
+1 365
012E +1 366 check_serial:
012E 3098FB +1 367 jnbscon.0,r1_check_serial
0131 C298 +1 368 clr scon.0
0133 E599 +1 369 MOV A,SBUF
0135 B44103 +1 370 cjne a,#cmd_track1_side1,c1_check_serial
0138 31C9 +1 371 call track1_side1
013A 22 +1 372 ret
+1 373
+1 374
013B +1 375 c1_check_serial:
013B B44203 +1 376 cjne a,#cmd_track1_side2,c2_check_serial
013E 31D9 +1 377 call track1_side2
0140 22 +1 378 ret
+1 379
+1 380
0141 +1 381 c2_check_serial:
0144 31EC +1 383 call track2_side1

41
0146 22 +1 384 ret
+1 385
+1 386
014A 31FC +1 389 call track2_side2
014C 22 +1 390 ret
+1 391
+1 392
014D +1 393 c4_check_serial:
014D B44503 +1 394 cjne a,#cmd_gate_open,c5_check_serial
0150 11CE +1 395 call gate_open
0152 22 +1 396 ret
+1 397
+1 398
0153 B44603 +1 400 cjne a,#cmd_gate_close,c6_check_serial
0156 11B4 +1 401 call gate_close
0158 22 +1 402 ret
+1 403
+1 404
0159 22 +1 406 ret

42
407
408 ;$include(display.inc)
409 ;$include (sametrack.inc)
015A +1 410 check_same_track:
015A 3161 +1 411 call check_sametracksensor1
015C 3197 +1 412 call check_sametracksensor2
015E 22 +1 413 ret
+1 414
+1 415
+1 416
+1 417
+1 418
015F +1 419 R1_check_sametracksensor1:
+1 420 ;NOOBSTACLE
015F D3 +1 421 SETB C
0160 22 +1 422 RET
+1 423
0161 +1 424 check_sametracksensor1:
0161 3094FB +1 425 jnb SENSOR3,R1_check_sametracksensor1
0164 7F30 +1 426 mov r7,#30h
0166 +1 427 deb1_loopa:
0166 3094F8 +1 428 jnbSENSOR3,check_sametracksensor1
0169 DFFB +1 429 djnzr7,deb1_loopa
016B 7433 +1 430 mova,#s_location3
016D 3105 +1 431 call send

43
016F 2094FD +1 432 jbsensor3,$
+1 433
0172 E534 +1 434 mova,sametrack_ram
0174 B4000C +1 435 cjne a,#00h,c1_check_sametracksensor1
0177 C2B6 +1 436 clr led_red1
0179 D2B4 +1 437 setbled_green1
017B D2B5 +1 438 setbled_green
017D D2B7 +1 439 setbled_red
017F 753401 +1 440 movsametrack_ram,#01h
0182 22 +1 441 ret
+1 442
+1 443
0183 +1 444 c1_check_sametracksensor1:
0183 B4020E +1 445 cjne a,#02h,c2_check_sametracksensor1
0186 C2B5 +1 446 clr led_green
0188 C2B4 +1 447 clr led_green1
018A D2B7 +1 448 setbled_red
018C D2B6 +1 449 setbled_red1

44
018E 753400 +1 450 mov sametrack_ram,#00h
0191 1137 +1 451 CALL LDELAY
0193 22 +1 452 ret
+1 453
+1 454
+1 455
0194 +1 456 c2_check_sametracksensor1:
0194 22 +1 457 ret
+1 458
+1 459
+1 460 ;*****************************************************************
+1 461 ;*****************************************************************
+1 462 ;*****************************************************************
+1 463 ;*****************************************************************
+1 464
0195 +1 465 R1_check_sametracksensor2:
+1 466 ;NOOBSTACLE
0195 D3 +1 467 SETB C
0196 22 +1 468 RET
+1 469
0197 +1 470 check_sametracksensor2:
0197 3095FB +1 471 jnb SENSOR4,R1_check_sametracksensor2
019A 7F30 +1 472 movr7,#30h

45
019C +1 473 deb1_loopb:
019C 3095F8 +1 474 jnbSENSOR4,check_sametracksensor2
019F DFFB +1 475 djnzr7,deb1_loopb
01A1 7434 +1 476 mov a,#s_location4
01A3 3105 +1 477 call send
01A5 2095FD +1 478 jb sensor4,$
+1 479
+1 480
01A8 E534 +1 481 mova,sametrack_ram
01AA B4000C +1 482 cjne a,#00h,c1_check_sametracksensor2
01AD C2B7 +1 483 clr led_red
01AF D2B5 +1 484 setbled_green
01B1 D2B4 +1 485 setbled_green1
01B3 D2B6 +1 486 setbled_red1
01B5 753402 +1 487 movsametrack_ram,#02h
01B8 22 +1 488 ret
+1 489
+1 490
01B9 +1 491 c1_check_sametracksensor2:
01B9 B4010C +1 492 cjne a,#01h,c2_check_sametracksensor2
01BC C2B5 +1 493 clr led_green
01BE C2B4 +1 494 clr led_green1
01C0 D2B7 +1 495 setbled_red
01C2 D2B6 +1 496 setbled_red1
01C4 753400 +1 497 movsametrack_ram,#00h

46
01C7 22 +1 498 ret
+1 499
01C8 +1 500 c2_check_sametracksensor2:
01C8 22 +1 501 ret
502
503 ;$include (trackswitching.inc)
01C9 +1 504 track1_side1:
01C9 309004 +1 505 jnbtracksw_fb1,r1_track1_side1
01CC 5131 +1 506 call track1_close
01CE 80F9 +1 507 jmptrack1_side1
+1 508
01D0 +1 509 r1_track1_side1:
01D0 5123 +1 510 call track1_stop
01D2 D201 +1 511 setbtrack1_side1_f
01D4 7437 +1 512 mova,#s_track1_side1
01D6 3105 +1 513 call send
01D8 22 +1 514 ret
+1 515

47
+1 516
01D9 +1 517 track1_side2:
01D9 30010B +1 518 jnbtrack1_side1_f,r1_track1_side2
01DC 512A +1 519 call track1_open
01DE 510F +1 520 call track_delay
01E0 5123 +1 521 call track1_stop
01E2 7438 +1 522 mova,#s_track1_side2
01E4 3105 +1 523 call send
01E6 22 +1 524 ret
+1 525
01E7 +1 526 r1_track1_side2:
01E7 7438 +1 527 mova,#s_track1_side2
01E9 3105 +1 528 call send
01EB 22 +1 529 ret
+1 530
+1 531
+1 532
+1 533
;*********************************************************************
+1 534
;*********************************************************************
+1 535
;*********************************************************************

48
+1 536
;*********************************************************************
+1 537
01EC +1 538 track2_side1:
01EC 309604 +1 539 jnbtracksw_fb2,r1_track2_side1
01EF 5146 +1 540 call track2_close
01F1 80F9 +1 541 jmptrack2_side1
+1 542
01F3 +1 543 r1_track2_side1:
01F3 5138 +1 544 call track2_stop
01F5 D202 +1 545 setbtrack2_side1_f
01F7 7439 +1 546 mov a,#s_track2_side1
01F9 3105 +1 547 call send
01FB 22 +1 548 ret
+1 549
+1 550
01FC +1 551 track2_side2:
01FC 30020B +1 552 jnbtrack2_side1_f,r1_track2_side2
01FF 513F +1 553 call track2_open
0201 510F +1 554 call track_delay
0203 5138 +1 555 call track2_stop
0205 7430 +1 556 mov a,#s_track2_side2
0207 3105 +1 557 call send
0209 22 +1 558 ret
+1 559
020A +1 560 r1_track2_side2:

49
020A 7430 +1 561 mov a,#s_track2_side2
020C 3105 +1 562 call send
020E 22 +1 563 ret
+1 564
+1 565
+1 566
+1 567
+1 568
;*********************************************************************
+1 569
;*********************************************************************
+1 570
;*********************************************************************
+1 571
;*********************************************************************
020F +1 572 track_delay:
020F 7530FF +1 573 mov delay0,#0ffh
0212 +1 574 l1_track_delay:
0212 7531FF +1 575 movdelay1,#0ffh
0215 +1 576 l2_track_delay:
0215 753201 +1 577 MOV DELAY2,#1
0218 D532FD +1 578 DJNZDELAY2,$
021B 00 +1 579 NOP
021C D531F6 +1 580 djnzdelay1,l2_track_delay

50
021F D530F0 +1 581 djnzdelay0,l1_track_delay
0222 22 +1 582 ret
+1 583
;*********************************************************************
+1 584
;*********************************************************************
+1 585
;*********************************************************************
+1 586
;*********************************************************************
+1 587
0223 +1 588 track1_stop:
0223 C280 +1 589 clr en2
0225 C281 +1 590 clr in2a
0227 C282 +1 591 clr in2b
0229 22 +1 592 ret
+1 593
+1 594
+1 595
022A +1 596 track1_open:
022A D280 +1 597 setben2
022C D281 +1 598 setbin2a
022E C282 +1 599 clr in2b
0230 22 +1 600 ret
+1 601

51
+1 602
0231 +1 603 track1_close:
0231 D280 +1 604 setben2
0233 C281 +1 605 clr in2a
0235 D282 +1 606 setbin2b
0237 22 +1 607 ret
+1 608
+1 609
+1 610
+1 611
;*********************************************************************
+1 612
;*********************************************************************
+1 613
;*********************************************************************
+1 614
;*********************************************************************
+1 615
0238 +1 616 track2_stop:
0238 C283 +1 617 clr en1
023A C284 +1 618 clr in1a
023C C285 +1 619 clr in1b
023E 22 +1 620 ret
+1 621
+1 622
+1 623
023F +1 624 track2_open:

52
023F D283 +1 625 setben1
0241 D284 +1 626 setbin1a
0243 C285 +1 627 clr in1b
0245 22 +1 628 ret
+1 629
+1 630
0246 +1 631 track2_close:
0246 D283 +1 632 setben1
0248 C284 +1 633 clr in1a
024A D285 +1 634 setbin1b
024C 22 +1 635 ret
636
637 end

53
SYMBOL TABLE LISTING
------ ----- -------
N A ME T Y P E V A L U E ATTRIBUTES
BAUDRATE. . . . . . . . . C ADDR 00F9H A
BUZZER. . . . . . . . . . B ADDR 00A0H.6 A
C1_CHECK_SAMETRACKSENSOR1 C ADDR 0183H A
C1_CHECK_SAMETRACKSENSOR2 C ADDR 01B9H A
C1_CHECK_SENSOR1. . . . . C ADDR 007EH A
C1_CHECK_SENSOR2. . . . . C ADDR 00AAH A
C1_CHECK_SERIAL . . . . . C ADDR 013BH A
C1_SEND_DPTR_STRING . . . C ADDR 0125H A
C2_CHECK_SAMETRACKSENSOR1 C ADDR 0194H A
C2_CHECK_SAMETRACKSENSOR2 C ADDR 01C8H A
C2_CHECK_SENSOR1. . . . . C ADDR 0087H A
C2_CHECK_SENSOR2. . . . . C ADDR 00B3H A
C2_CHECK_SERIAL . . . . . C ADDR 0141H A
C4_CHECK_SERIAL . . . . . C ADDR 014DH A

54
CHECK_GATE. . . . . . . . C ADDR 005AH A
CHECK_SAMETRACKSENSOR1.. C ADDR 0161H A
CHECK_SAMETRACKSENSOR2.. C ADDR 0197H A
CHECK_SAME_TRACK.. . . . C ADDR 015AH A
CHECK_SENSOR1. . . . . . C ADDR 0061H A
CHECK_SENSOR2. . . . . . C ADDR 008AH A
CHECK_SERIAL.. . . . . . C ADDR 012EH A
CMD_GATE_CLOSE. . . . . . D ADDR 0046H A
CMD_GATE_OPEN . . . . . . D ADDR 0045H A
CMD_TRACK1_SIDE1. . . . . D ADDR 0041H A
DEB1_LOOP . . . . . . . . C ADDR 0066H A
DEB1_LOOPA. . . . . . . . C ADDR 0166H A
DEB1_LOOPB. . . . . . . . C ADDR 019CH A
DEB2_LOOP . . . . . . . . C ADDR 008FH A
DELAY . . . . . . . . . . C ADDR 0044H A
DELAY0. . . . . . . . . . N NUMB 0030H A
DELAY1. . . . . . . . . . N NUMB 0031H A
DELAY2. . . . . . . . . . N NUMB 0032H A
EN1 . . . . . . . . . . . B ADDR 0080H.3 A
EN2 . . . . . . . . . . . B ADDR 0080H.0 A
EN3 . . . . . . . . . . . B ADDR 00A0H.5 A
EN4 . . . . . . . . . . . B ADDR 00A0H.2 A

55
FORWARD. . . . . . . . . C ADDR 00EBH A
GATE_CLOSE. . . . . . . . C ADDR 00B4H A
GATE_CLOSE_F. . . . . . . B ADDR 0020H.0 A
GATE_CLOSE_SENSOR. . . . B ADDR 0090H.1 A
GATE_OPEN . . . . . . . . C ADDR 00CEH A
IN1A.. . . . . . . . . . B ADDR 0080H.4 A
IN1B. . . . . . . . . . . B ADDR 0080H.5 A
IN2A.. . . . . . . . . . B ADDR 0080H.1 A
IN2B. . . . . . . . . . . B ADDR 0080H.2 A
IN3A.. . . . . . . . . . B ADDR 00A0H.3 A
IN3B. . . . . . . . . . . B ADDR 00A0H.4 A
IN4A.. . . . . . . . . . B ADDR 00A0H.1 A
IN4B. . . . . . . . . . . B ADDR 00A0H.0 A
L1_DELAY. . . . . . . . . C ADDR 0047H A
L1_LDELAY . . . . . . . . C ADDR 003AH A
L1_TRACK_DELAY. . . . . . C ADDR 0212H A
L2_DELAY. . . . . . . . . C ADDR 004AH A
L2_LDELAY . . . . . . . . C ADDR 003DH A

56
L2_TRACK_DELAY. . . . . . C ADDR 0215H A
LDELAY. . . . . . . . . . C ADDR 0037H A
LED_GREEN . . . . . . . . B ADDR 00B0H.5 A
LED_GREEN1. . . . . . . . B ADDR 00B0H.4 A
LED_RED . . . . . . . . . B ADDR 00B0H.7 A
LED_RED1. . . . . . . . . B ADDR 00B0H.6 A
LOOP.. . . . . . . . . . C ADDR 002FH A
LSEND1. . . . . . . . . . C ADDR 0107H A
NEWLINE . . . . . . . . . C ADDR 0115H A
P0. . . . . . . . . . . . D ADDR 0080H A
P1. . . . . . . . . . . . D ADDR 0090H A
P2. . . . . . . . . . . . D ADDR 00A0H A
P3. . . . . . . . . . . . D ADDR 00B0H A
R1_CHECK_SAMETRACKSENSOR1 C ADDR 015FH A
R1_CHECK_SAMETRACKSENSOR2 C ADDR 0195H A
R1_CHECK_SENSOR1. . . . . C ADDR 005FH A
R1_CHECK_SENSOR2. . . . . C ADDR 0088H A
R1_CHECK_SERIAL . . . . . C ADDR 012CH A
R1_GATE_CLOSE . . . . . . C ADDR 00BDH A
R1_GATE_OPEN. . . . . . . C ADDR 00C8H A
R1_SEND_DPTR_STRING . . . C ADDR 012BH A
R1_TRACK1_SIDE1 . . . . . C ADDR 01D0H A
R1_TRACK1_SIDE2 . . . . . C ADDR 01E7H A

57
R1_TRACK2_SIDE1 . . . . . C ADDR 01F3H A
R1_TRACK2_SIDE2 . . . . . C ADDR 020AH A
RECEIVE . . . . . . . . . C ADDR 010DH A
REVERSE . . . . . . . . . C ADDR 00F2H A
SAMETRACK_RAM. . . . . . N NUMB 0034H A
SBUF. . . . . . . . . . . D ADDR 0099H A
SCON.. . . . . . . . . . D ADDR 0098H A
SDELAY. . . . . . . . . . C ADDR 0051H A
SEND.. . . . . . . . . . C ADDR 0105H A
SEND_DPTR_STRING.. . . . C ADDR 011EH A
SENSOR1 . . . . . . . . . B ADDR 0090H.3 A
SENSOR2 . . . . . . . . . B ADDR 0090H.2 A
SENSOR3 . . . . . . . . . B ADDR 0090H.4 A
SENSOR4 . . . . . . . . . B ADDR 0090H.5 A
SENSOR_RAM.. . . . . . . N NUMB 0033H A
SL1_DELAY . . . . . . . . C ADDR 0053H A
SP.. . . . . . . . . . . D ADDR 0081H A
STOP.. . . . . . . . . . C ADDR 00E4H A
S_GATE_CLOSE. . . . . . . D ADDR 0036H A
S_GATE_OPEN . . . . . . . D ADDR 0035H A
S_LOCATION1. . . . . . . D ADDR 0031H A
S_TRACK1_SIDE1. . . . . . D ADDR 0037H A

58
TCON.. . . . . . . . . . D ADDR 0088H A
TH1 . . . . . . . . . . . D ADDR 008DH A
TMOD. . . . . . . . . . . D ADDR 0089H A
TRACK1_CLOSE.. . . . . . C ADDR 0231H A
TRACK1_OPEN . . . . . . . C ADDR 022AH A
TRACK1_SIDE1. . . . . . . C ADDR 01C9H A
TRACK1_SIDE1_F. . . . . . B ADDR 0020H.1 A
TRACK1_SIDE2. . . . . . . C ADDR 01D9H A
TRACK1_STOP. . . . . . . C ADDR 0223H A
TRACK2_CLOSE.. . . . . . C ADDR 0246H A
TRACK2_OPEN . . . . . . . C ADDR 023FH A
TRACK2_SIDE1. . . . . . . C ADDR 01ECH A
TRACK2_SIDE1_F. . . . . . B ADDR 0020H.2 A
TRACK2_SIDE2. . . . . . . C ADDR 01FCH A
TRACK2_STOP. . . . . . . C ADDR 0238H A

59
TRACKSW_FB1 . . . . . . . B ADDR 0090H.0 A
TRACKSW_FB2 . . . . . . . B ADDR 0090H.6 A
TRACK_DELAY . . . . . . . C ADDR 020FH A
REGISTER BANK(S) USED: 0
ASSEMBLY COMPLETE. 0 WARNING(S),0ERROR(S)

60
B] Visual Basic programming
OptionExplicit
DimInputStringBufferAsString
DimWriteStringBufferAsString
DimTagno As String
'Dim countAs Integer
Private Subcmdconnect_Click()
If cmdconnect.Caption="CONNECT"Then
MSComm1.CommPort= txtcommport.Text
MSComm1.PortOpen=True
cmdconnect.Caption="DISCONNECT"
MSComm1.RThreshold=1
ElseIf cmdconnect.Caption="DISCONNECT"Then
MSComm1.PortOpen=False
cmdconnect.Caption="CONNECT"
End If
End Sub
Private SubCommand1_Click()
MSComm1.Output= "E"
End Sub
MSComm1.Output= "A"

61
End Sub
MSComm1.Output= "F"
End Sub
MSComm1.Output= "B"
End Sub
Private Sub Command5_Click()
MSComm1.Output= "C"
End Sub
MSComm1.Output= "D"
End Sub
Private SubForm_Load()
Open"d:attendance_logs.txt"ForAppendAs#1
Close #1
End Sub

62
Private SubMSComm1_OnComm()
If MSComm1.CommEvent= comEvReceiveThen
Text1.Text= ""
Text1.Text=MSComm1.Input
If Text1.Text=1 ThenLabel3.Caption=" C.S.T.Crossing"
If Text1.Text=2 ThenLabel3.Caption=" C.S.T.Crossing"
If Text1.Text=3 ThenLabel3.Caption=" KALYAN JUNCTION"
If Text1.Text=4 ThenLabel3.Caption=" KALYAN JUNCTION"
If Text1.Text=5 ThenLabel5.Caption=" OPEN "
If Text1.Text=6 ThenLabel5.Caption=" CLOSE "
If Text1.Text=7 ThenLabel1.Caption=" SIDE 1 "
If Text1.Text=1 Then
If Timer2.Enabled=True Then
Timer2.Enabled=False
Text2.Text=(100000 / Val(Text4.Text)) /20
Label7.Caption=Mid((100000 / Val(Text4.Text)) /20, 1, 4)
Else
Text4.Text=1
Timer2.Enabled=True

63
End If
End If
If Text1.Text= 2 Then
Else
Text4.Text=1
Timer2.Enabled=True
End If
End If
If Text1.Text=3 Then
Else
Text3.Text=1
Timer1.Enabled=True
End If

64
End If
If Text1.Text= 4 Then
Else
Text3.Text=1
Timer1.Enabled=True
EndIf
End If
End If
End Sub
Private SubTimer1_Timer()
Timer1.Enabled=True
'count = count + 1
Text3.Text= Text3.Text+1
End Sub
Private SubTimer2_Timer()
Timer2.Enabled=True
Text4.Text= Text4.Text+1
End Sub

65
Software Display Screen

66
CIRCUIT
PREPARATION

67
CIRCUIT PREPARATION
PCB Designing and manufacturing
Printed Circuit Board Layout:
The PCB layout for circuit is an attach in annexure D.Board consist of insulating material
mostly copper-clad boards are used instead of copper, silver and gold can also be used but, as
copper is chipper mostly it is preferable. The material conducting pattern serves as conducting
medium for electronic component that are assembled on board components are mounted by lead
passing through holes that are drilled or punched on the based material and foil. These leads are
solder to the conducting pattern to form complete PCB in glass, glass epoxy, and epoxy paper
phenolic etc.The copper foil on the base material is developed by the process of electrode
position ion etching process.
Some of the elements are used are as follows:
 Fecl3
 Chromic acid, etc.
But fecl3 is most commonly used in etching process .PCB acts as a heat sink.
ARTWORK OF PCB:
Perfect artwork is mostly important process in production of PCB.The circuit is initially
tested and location of components is fixed. Artwork is the drawing showing conduction pattern
on PC.After testing the circuit rough layout is prepared on paper then that layout is transferred on
PCB by using PCB side. The artwork can also be prepared on transparent paper with sticking
tapes and self adhesive in various ranges.

68
FILMING OF PCB:
To prepare a PCB at home following procedure is adopted
Measure the dimensions of all components e.g.resister, capacitor, inductor; etc. are prepared a
layout using component mounting rules:
 Using the trace paper or carbon paper draw the mirror image of the figure.
 Draw this image on cu cladding of PCB by using PCB pen, pencil, tapes and pads then
drill the holes by using drilling machine.
 After drilling points the conductor tracks by using oil paints of good quality and live it
for drying.
 After drying the points put the PCB in fecl3 solution for etching. If you want fast etching
add some drop of HCL during etching unwanted cu dissolved in fecl3.
 After etching washes it with water and if you remove the point then used acetone.
 Then mount the component opposite side of tracks.
 Cut the leads of proper length and solder all the terminal of the components.
 In this PCB is fabricated manually.
For PCB designing you should have following things:
 Detail circuit diagram.
 Physically each component with you.
 To determine the size of PCB.
 Layout and filming.
 PCB manufacturing

69
Tracing of the layout from paper to copper clad:
First of all circuit layout is taken on tracing paper with exact dimension of all component.
Now placing this paper on copper clad under carbon paper, trace the layout the copper clad. It
should be notice that the tracing on the clad should be accurate.
Applying non etching material on the layout:
Applying non etching material on layout is done manually.The non etching material are
drafting aids, oil paints, etc.on the PCB drafting aids are used, because more linearity conducting
are obtained .the drafting’s aids are different shapes and z-size for every component are should
be no crack on the drafting aids, because due to at this after etching their will be no conduction
between two lines.
Etching procedure:
After applying the non etching on the copper clad then this copper clad is kept in fecl3
solution for etching procedure. The etching procedure longs for the about 5 or 6 hours. During
the etching procedure the copper under the drafting aids does not get etches while all other
copper on the clad get etched and only the layout remains.
Cleaning the PCB and remaining non etch materials:

70
After the etching and cleaning of PCB is done. It is done with the help of soap solution
and brush. To remove the transfer pattern with the cotton swab-dipped in the pattern remover
solution. Again wash with the soap and water then dry it.
• Drilling:-
After the PCB is ready, drilling is necessary. Drilling is done with the help of hand drill
or machine. For mounting of component proper drilling (holes) are necessary. The holes are of
dimension so that the terminals of each component and pin of the IC can easily pass through it to
make contact with conducting line on the PCB.
Small drills for PCB use usually come with either a set of collets of various sizes or a 3-jaw
chuck. For accuracy, however, 3-jaw chucks aren't brilliant, and small drill sizes below 1mm
quickly form grooves in the jaws, preventing good grip. Need of good strong light on the board
when drilling to ensure accuracy. Typical hole sizes is 0.8mm.
Component Placement & Design:-
The basic steps required for Component Placement & Design.
 Set snap grid, visible grid, and default track/pad sizes.
 Throw down all the components onto the board.
 Divide and place components into functional “building blocks” where possible.
 Identify layout critical tracks on circuit and route them first.

71
 Place and route each building block separately, off the board.
 Move completed building blocks into position on main board.
 Route the remaining signal and power connections between blocks.
This is by no means a be-all and end-all check list; it’s highly variable depending on many
factors. The best way to start layout is to get all components onto the screen first and place them
down manually.
• Soldering:-
It is process of joining two metals together by the use of solder alloy to form a reliable
electrical path.
Soldering considerations need to taken into account when laying out board. There are
three basic soldering techniques - hand, wave, and reflow. Hand soldering is the traditional
method typically used for prototypes and small production runs. Major impacts when laying out
board include suitable access for the iron, and thermal relief for pads.
Procedure of soldering:
1) clean all components, terminals and substrates
2) Apply flux
3) Place the soldering iron with right tip size, touching both the lid and pad.
4) From initially a heat bridge between the soldering iron and the lead pad junction with a
little solder to increase the thermal linkage area.
5) Feed the solder wire starting from the heat bridge all around the lead.
6) Remove the solder and soldering iron simultaneously.
7) There should not be any relative movement between the components under solidification
and the working table.
8) Check the joint

72
Solder Mask:-
A solder mask is a thin polymer coating on your board which surrounds pads to help
prevent solder from bridging between pins. This is essential for surface mount and fine pitch
devices. The solder mask typically covers everything except pads and vias.
• Electrical Testing:-
We have finished PCB checked for electrical continuity and shorts at the time of
manufacture. This is done with an automated “flying probe” or “DMM”. It checks that the
continuity of the tracks matches your PCB file.
Trouble Shooting:
 The different protocols that we tested were Sony, Fujitsu, NEC, Fairchild etc. But this
was unable to detect IR sensor, so we had used RC5 by Phillips.
 The intensity of RC5 protocol was very high. Hence it was try to reduce by using an
insulation tape.
 The only problem was with the line of sight .the solution to this is that the transmitter and
receiver should match with line of sight to detect.

73
ADVANTAGES,
LIMITATIONS&

74
APPLICATIONS
ADVANTAGES, DISADVANTAGES,
FUTURE SCOPE
ADVANTAGES:-
1. Large amount of accidents can be avoided.
2. Continuous updates of train position at master control.
3. Large amount of man power is saved and thereby reduction in the cost of wages for
railway is possible.
4. Controlling of various features by the master controller.
5. Well management can be possible due to sufficient data.
6. Possibility of human error is avoided.
7. Flawless track switching is possible due to the master controller.
DISADVANTAGES:-
1. Due to use of IR sensors, the major drawback is the line of sight and cause fake
detection.
2. Accidents due to absence of track cannot be overcome.
3. Implementation cost is high.
4. We cannot identify the name of train running on the track.
FUTURE SCOPE:-
1. “SHIELD” technology or the anti collision devices can be used to avoid train collision.
2. GPS system can be used to get the updated information about the train.
3. Weight sensors can be used for the automatic railway control.

75
4. Track vacancy detection can be possible due to ATP code transmission.
COSTSHEET

76
Cost Sheet

77
Sr.no. Components Quantity Cost Total
1 Microcontroller IC 89S52 1 70/- 70/-
2 Crystal 11.0592Mhz. 1 8/- 8/-
3 Diode 1N4007 4 1/- 4/-
4 Resistor 10kΩ 10 1/- 10/-
5 Resistor 2.2kΩ 10 1/- 10/-
6 Resistor 220Ω 3 1/- 3/-
7 Capacitor 1000uf 2 10/- 20/-
8 Capacitor 100uf 5 2/- 10/-
9 Capacitor 10uf 4 1/- 4/-
10 Capacitor 33pf 4 3/- 12/-
11 8 pin Connector 2 10/- 20/-
12 2 pin Connector 6 5/- 30/-
13 Transistor BC 547 2 1/- 2/-
14 Heat Sink 1 25/- 25/-
15 DC Motor 2 125/- 250/-
16 IC L293D 1 50/- 50/-
17 IR Sensor 4 125/- 500/-
18 LED 5 2/- 10/-
19 MAX 232 1 50/- 50/-
20 LCD 16x2 1 130/- 130/-
21 Resistor Package 2 10/- 20/-
22 IC BASE 4 10/- 40/-
23 Transformer 0-12V/500ma 1 150/- 150/-
24 IC 7805 1 10/- 10/-
25 IC 7812 1 10/- 10/-
26 Train Set 1 900/- 900/-
Total 2398/-

78
CONCLUSION

79
CONCLUSION
CONCLUSION:
In today’s industrial scenario, to survive in the global competition, every Agro-
based industry is forced to use automated process. Today’s industrial scenario demands use of
automated process because of global competition.
Automation system is more advantageous than manual system related parameters
are speed, time saving, accuracy, man power etc Knowing working principle, configuration
procedure & trouble shooting techniques along with designing of logic is a key factor in
industrial automation. It can be considered as the first serious attempt to fulfill the requirements
for a universal industry system. The automation standard provides a common set of compatible
services and capabilities to all industrial users.
Hence it is suggested that we put in more resources to research on new horizons
as early as possible for a better life for us!!

80
REFERENCE
REFERENCES

81
Books:-
 Microcontroller and embedded system. :- Mazidi
 Principle of electronics:-V.K. Mehta
 Applied Electronics:-R.S. Seddha
 Digital principle & application:-Malvino & Leach
 Real time operating system:- Dr. K.K.V. Prasad
Websites:-
 www.houstuff.com
 www.DNAtechindia.com
 www.wikipedia.com
 www.altavista.com
Search Engine:-
 www.google.com
 www.yahoo.com
 www.altavista.com
Magazines:-
 Electronics for you
 Electronics express

82
DATASHEET
&
PHOTOGRAPH

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97
RS232
Pin Signal Pin Signal
1 Data carrier detect 6 Data set ready
2 Receiveddata 7 Requesttosend
3 Transmitteddata 8 Clearto send
4 Data terminal ready 9 Ringindicator
5 Signal ground

98

99

100

101

102

103

104
PHOTOGRAPH

105

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INTELIGENT RAILWAY SYSTEM

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