Initial Testing PCB

Schematic of Circuit Board
For Temporary Testing of GSM Communicator and Scheduler

 PCB Layout

 Developed PCB

Ignition Sequence

OFF State
            Pins Short :  2~3

ON State

Pins Short:  1~4

Self Start

Pins Short:  1~4~5

Ignition Sequence Control Unit

 

Auto Choke Adjustment

Approach 1

Choke was pulled to one side by an elastic and to the other side by a motor; which could be controlled.

Problem

There was too much stress on the choke lever

 

Approach 2

Choke was couples on a CHAIN, which moved by a motor.

We installed two limit switches to confine the movement of chain within certain limits, to prevent any damage to choke lever.

Benefit

Choke could be stopped at any position without any excess stress. 

 

 Motor Control Unit

Generator Feedback Sensing Module

Will give a HIGH LOGIC signal whenever the Generator is on and vice versa.

Approach #1

Created a feedback module ourselves which gave +7Volts output upon 220volt / 50Hz input.

Problem

Due to poor isolation, there was too much noise at output, thus generating false outputs

 

Approach #2

We a Nokia 5Volt adapter J

Benefit

Good isolation and negligible noise content

Scheduler

ON Timer

Will turn On computer daily at specified time

OFF Timer

Will turn Off computer daily at specified time

Mobil Oil Countdown Timer 

Will monitor Running Hours of generator and will notify when time reduces to zero.

Simulation 

RTC (Real Time Clock)

 

RTC-DS1307

* Maintains time and calendar

*   Equipped with a pocket for backup cell (CR-2032) so that it could hold time and calendar for up-to 10 years even when the power of the reset of the circuit is cut-off.

 Simulation

 

GSM Features

Turn ON Generator *

Will turn On generator upon reception of this message

Message Syntax “ gnon ”

Turn OFF Generator *

Will turn Off generator upon reception of this message

Message Syntax “ gnoff ”

Generator Status Check *

Will reply the message with the current status of generator

Message Syntax “ status ”

Failure Message

Notification if generator does not start after several tries

Turning On Notification

Will send message to administrator whenever the generator turns On

Turning Off Notification

Will send message to administrator whenever the generator turns OFF

 

Development Sequence of GSM Communications

 

SMS Receiving Prototype

SMS Sending Prototype

Simulation

 

                                                                 (Proteus ISIS 7)

 

First Run..

Today we gave it a run on petrol, with our newly designed  auto-start system. It just had the basic functionality of turning the generator on when electricity from mains cut off, and turns off the generator when electricity from the mains resumed.

Here's a rough video in the dark!

Our generator has arrived!!

Hi everyone, here's our generator

Its a ''Matari MG5500E'', which is a 3.5KV gasoline (Petrol) generator. Its has manual as well as self-start option for starting. The choke is not auto-controlled, so we have to use a plunger or stepper to control the choke at a later stage for its autonomous auto-start operation.

As for now, it runs on petrol only, but soon we will be installing a natural-gas kit to it so that it could run on both fuels.

Load Switching Mechanism

Since I will be testing our ATS system on a 3.5Kv generator, thus max ampere rating of this generator will be ~15Amperes. So I will be using 30A-heavy duty relays (like those found in a common UPS).   

I have successfully tested operation of these relays on breadboard. Now i will soon be inserting them in a veroboard for further trials, until we make a final PCB of the whole circuit near the end of my project.

Feedback Sensing Module..

I have designed and tested a sensing module on a breadboard that could inform the microcontroller that if main 220V-50Hz electricity source (i.e. from WAPDA) is available or not.
Next I designed, etched and developed a PCB and enclosed that PCB in a regular adapter casing for insulation and protection.

RTC...

After successful testing of RTC (DS-1307) on bread board, I designed, etched and constructed a PCB that had a pocket for backup cell (CR-2032 [3v] ) so that it could hold time and calender even when the power of the reset of the circuit was cut-off.

GSM Controller continued..

Step 3:
Next I programmed the microcontroller (AT89S52) to send the same sequence of 'at-commands' through serial port. I verified via 'hyperterminal' that the microcontroller was sending those at commands in exact order, with proper delay. This part was really tough. It took me and my group-mate several nights to accomplish.

Step 4:   
It was the time for us to make a cable to connect mobile directly with the microcontroller, so we made a serial male-female cable with tx-rx pins in cross.
After a lot of hardware debugging we were able to successfully communicate mobile with the microcontroller.