Project Design And Development
Workshop Manual
Instrumentation Engineering Department
GPTC Palakkad
List of Experiments
1. Familiarize various tools used in soldering practice.
2.Soldering practice on simple resistive circuit.
3. Familiarization various types of relays.
4. Switching on/off a lamp using relay.
5. Familiarization of arduino UNO.
Workshop Practice no; 1 Date:
Familiarize various tools used in soldering practice
Aim: To study various tools used in soldering practice.
Theory:
Soldering is the process of joining two or more metals using an alloy metal having low
melting point to establish electrical connections. Hand soldering and machine soldering are
the two types of soldering methods.
Solder: Solder is used for joining two or more metals at temperature below their melting
point. The popularly used solders are the alloy of tin (63%) and lead (47%) that metals at 183
degree Celsius and solidifies when it cools. Melting points of tin and lead are 232 degree
Celsius and 327 degree Celsius respectively. When tin and lead are mixed in 63:47 ratios, it
becomes melted at 183 degree Celsius.
Soldering fluxes: In order to make the surfaces accept the solder readily, the component
terminals should be free from oxides and other obstructing films. Soldering flux cleans the
oxides from the surface of metal. The leads should be cleaned chemically or by scraping
using a blade. Small amount of solder should be coated on the cleaned portion of the
component leads and the bit of the soldering iron. This process is called tinning. Zinc
chloride, ammonium chloride and rosin are the most commonly used fluxes. These are
available in petroleum jelly as paste flux. The residues which remain after the soldering may
be washed out with isopropyl alcohol or Acetone.
Soldering tools:
Soldering iron: It is used to melt the solder and apply at the joints in the circuit. It operates in
230V mains supply. The normal power rating of the soldering iron is 10W, 25W, 35W, 65W,
and 125W. 10W and 25W are sufficient for light duty work. The iron bit at the tip of it gets
heated up within a few minutes. The tip of the bits are either pointed or tapered. Pointed tips
are useful for soldering very accurate and small circuits. It needs only a very small amount of
solder. In the laboratory, tapered bits are normally used.
Soldering irons are available in simple to complex types, but they all function roughly the
same.
Parts of an iron and the different types of irons.
● Tips. The tip is the part of the iron that heats up and allows solder to flow around the
two components being joined.
● The tip actually transfers heat, raising the temperature of the metal components to the
melting point of the solder, and the solder melts accordingly. Tips come in a variety of
sizes and shapes to accommodate any component.
Soldering iron types of tips . From left to right, the bevel tip (aka hoof tip), two conical tips
with varying widths, and the chisel tip
Wand - The wand is the part of the iron that holds the tip. This is also the part that is handled
by the user. Wands are usually made of a variety of insulating materials (such as rubber) to
prevent the heat of the tip from transferring to the outside of the wand, but they also house
wires and metal contacts that transfer heat from the base or outlet to the tip. This dual role of
heating and preventing burns makes a high quality wand much appreciated.
Base - The base of the soldering iron is the control box that allows the adjusting of
temperatures. The wand attaches to the base and receives its heat from the electronics inside.
There are analog bases, which have a dial that controls the temperature, and there are digital
bases, which have buttons to set the temperature and a display that tells the current
temperature. Some bases even have extra features such as heat profiles that allow you to
quickly change the amount of heat provided to the tip for soldering a variety of components.
Soldering Iron stand(Cradle): It is used to place the soldering safely when it is not in use.
Soldering gun: It is gun shaped soldering tool used especially when more heat is required. Its
trigger is switch that controls the ac power.
Desolder pump: It is vacuum pump used to remove the solder when melted by the soldering
iron while desoldering the connections. When the solder metals, a trigger on the desolder
pump should be activated to create vacuum. This vacuum pulls the solder in to the tube.
Brass Sponge - As you solder, your tip will tend to oxidize, which means it will turn black
and not want to accept solder. Brass sponges have become the standard for tip cleaning. Brass
sponges pull the excess solder from your tip while allowing the tip to maintain its current heat
level.
Soldering Accessories
Tools that will aid in soldering work are:-
● Solder Wick - is the eraser to soldering’s pencil. When dealing with issues such as
jumpers or the removal of parts (desoldering), solder wick comes in very handy.
Solder wick is comprised of thin copper wire braided together. Solder is soaked
(wicked) up by the copper allowing you to “erase” extra globs of solder
● Tip Tinner - is a chemical paste used to clean the tip of your soldering iron. It is
composed of a mild acid that helps remove baked on residue (like when you
accidentally melt your tip on a component) and helps prevent oxidation (the nasty black
stuff) that accumulates on your soldering tip when not in use.
● Flux Pen - Flux is a chemical agent that aids in the flowing of lead-free solder. Flux
pens allow you to dab stubborn components with liquid flux to create better looking
solder joints.
Result:
Date:
Workshop Practice no;2
Soldering practice on simple resistive circuit
Aim: To practice soldering and desoldering on the given circuit,and to find
equivalent resistance of circuit by both measurement and calculation
Materials Required:Soldering iron, Solder, Flux, De soldering pump, Knife,
Nose plier and General purpose PCB
Circuit:
Rules of soldering:
⮚ Clean the component leads using a blade. Apply a little flux on the leads. Take a
solder on soldering iron and apply the molten solder on the leads. This process is
called tinning
⮚ Clean the tips of the soldering iron. Keep the bit always clean from oxide formulation
while soldering.
⮚ Do not over heat the PCB and devices. Soldering iron must be done in minimum time
to avoid dry-soldering and heating up of the components.
⮚ Do not use excess solder or flux.
Sample calculation:
Procedure:
1. Make a lay out of the connections of the component in the circuit. Plug in the chord
of soldering iron into the mains supply to get it heated.
2. Tin the leads and bend them according to the needs.
3. Mount the component on the PCB, apply flux on the joints and solder the joints.
4. Wash the residue using Acetone and brush
5. Practice desoldering a soldered circuit, using soldering iron and desoldering pump.
Result:
Date:
Workshop Practice no; 3
To Familiarize with relays and its terminologies
Aim: To study different type of relays, its associated terms.
Theory:
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such as solid-state
relays. Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where several
circuits must be controlled by one signal. The first relays were used in long distance telegraph
circuits as amplifiers: they repeated the signal coming in from one circuit and re-transmitted
it on another circuit. Relays were used extensively in telephone exchanges and early
computers to perform logical operations.
Since relays are switches, the terminology applied to switches is also applied to relays; a
relay switches one or more poles, each of whose contacts can be thrown by energizing the
coil.
Normally open (NO) contacts connect the circuit when the relay is activated; the circuit is
disconnected when the relay is inactive. It is also called a "Form A" contact or "makes"
contact. NO contacts may also be distinguished as "early-make" or "NOEM", which means
that the contacts close before the button or switch is fully engaged.
Normally closed (NC) contacts disconnect the circuit when the relay is activated; the circuit
is connected when the relay is inactive. It is also called a "Form B" contact or "break"
contact. NC contacts may also be distinguished as "late-break" or "NCLB", which means that
the contacts stay closed until the button or switch is fully disengaged.
Change-over (CO), or double-throw (DT), contacts control two circuits: one normally open
contact and one normally closed contact with a common terminal. It is also called a "Form C"
contact or "transfer" contact ("break before make"). If this type of contact has a "make before
break" action, then it is called a "Form D" contact.
The following designations are commonly encountered:
SPST – Single Pole Single Throw. These have two terminals which can be connected or
disconnected. Including two for the coil, such a relay has four terminals in total. It is
ambiguous whether the pole is normally open or normally closed. The terminology "SPNO"
and "SPNC" is sometimes used to resolve the ambiguity
SPDT – Single Pole Double Throw. A common terminal connects to either of two others.
Including two for the coil, such a relay has five terminals in total.
DPST – Double Pole Single Throw. These have two pairs of terminals. Equivalent to two
SPST switches or relays actuated by a single coil. Including two for the coil, such a relay has
six terminals in total. The poles may be Form A or Form B (or one of each).
DPDT – Double Pole Double Throw. These have two rows of change-over terminals.
Equivalent to two SPDT switches or relays actuated by a single coil. Such a relay has eight
terminals, including the coil.
Latching relay
A latching relay (also called "impulse", "keep", or "stay" relays) maintains either contact
position indefinitely without power applied to the coil. The advantage is that one coil
consumes power only for an instant while the relay is being switched, and the relay contacts
retain this setting across a power outage. A latching relay allows remote control of building
lighting without the hum that may be produced from a continuously (AC) energized coil.
In one mechanism, two opposing coils with an over-center spring or permanent magnet hold
the contacts in position after the coil is de-energized. A pulse to one coil turns the relay on
and a pulse to the opposite coil turns the relay off. This type is widely used where control is
from simple switches or single-ended outputs of a control system and such relays are found in
avionics and numerous industrial applications.
Result:
Date:
Workshop practice No.
CONTROLLING A LAMP USING A RELAY
Aim
To design and setup a circuit to control the ON/OFF status of a device(lamp)
Components Required
Sl no. Component Specification Quantity
1 SPDT Relay 3 C/O MPC 24D 1
2 Bulb 230 V, 60W 1
3 DC power supply 1
4 Connecting wires
Theory
A relay is an electromagnetic switch operated by a relatively small electric current. It can turn ON or
OFF a much large electric current.The heart of the relay is an electromagnet(a coil of wire that
becomes a temporary magnet when electricity flows through it).
SPDT Relay (Single Pole Double Throw Relay):It is an electromagnetic switch. The relay unit we
use is PLA relays 3 C/O- MPC-24D. It is a plug-in type 11 pin relay. It has 3 SPDT relays in it.It
consists of a coil(terminal 2 &10), 3 common terminal (1,6,11), 3 normally closed terminals(4,5,8)
and 3 normally open terminals(3,7,9).
When the coil of an SPDT relay is at rest (not energized), the common terminal (1) and the normally
closed terminal (4) have continuity. When the coil is energized, the common terminal (1) and the
normally open terminal (3) have continuity. The diagram shows an SPDT relay at rest, when the coil
is not energised.
The aim of the experiment is to switch ON an electric bulb operating at 230V AC. For this purpose we
use 24V DC relay that can operate for 230v appliances. The bilb is connected across the common
terminal and normally open terminal. When the relay is energised the common terminal and normally
open terminal gets continuity and the bulb glows.
BASE WIRE CONFIGURATION OF RELAY
PROCEDURE
1.Check all the components to be used in the circuit diagram
2.Connections are made as shown in the circuit diagram.
3.Switch ON the power supply.
4.Check the ON/OFF status of the device by energising & de-energising the relay using switch.
5.Change the connections of the bulb to the NC contact and repeat the experiment.
CIRCUIT DIAGRAM
Result:
Date:
Workshop practice no.
Familiarization on Arduino UNO
Introduction
Arduino is an open-source platform for developing interactive electronic devices.Arduino
boards are able to read inputs - light on a sensor, a finger on a button, or a Twitter message -
and turn it into an output - activating a motor, turning on an LED, publishing something
online. You can tell your board what to do by sending a set of instructions to the
microcontroller on the board. Arduino provides a simple, standardized interface for
microcontrollers, which has led it to become a very popular tool for hobby projects, citizen
science tools, and even art installations. Arduino began in 2005 as a student project at the
Interaction Design Institute Ivrea in Ivrea, Italy.
Why Arduino?
· Inexpensive - Arduino boards are relatively inexpensive compared to other
microcontroller platforms.
· Cross-platform - The Arduino Software (IDE) runs on Windows, Macintosh OSX, and
Linux operating systems. Most microcontroller systems are limited to Windows.
· Simple, clear programming environment - The Arduino Software (IDE) is easy-to-use
for beginners, yet flexible enough for advanced users to take advantage of as well. For
teachers, it's conveniently based on the Processing programming environment, so
students learning to program in that environment will be familiar with how the Arduino
IDE works.
· Open source and extensible software - The Arduino software is published as open
source tools, available for extension by experienced programmers. The language can be
expanded through C++ libraries, and people wanting to understand the technical details
can make the leap from Arduino to the AVR C programming language on which it's
based.
Open source and extensible hardware - The plans of the Arduino boards are published
under a Creative Commons license, so experienced circuit designers can make their own
version of the module, extending it and improving it.
Arduino Board Description
Voltage Regulator
The Arduino Uno can be powered by USB cable or directly supplying 9-12v from the barrel
jack. The circuitry operates at 5v dc which in case input more than that is regulated with the
help of 7805 voltage regulator.
Crystal Oscillator
The crystal oscillator is the only way the arduino is able to calculate the time. There is a
number printed on the top of the crystal. The number indicates the frequency of the crystal,
in most of them the frequency is 16 MHZ or 16,000,000 hertz.
Reset Button
There is a reset button given which is used to restart the program running in the Arduino
uno. There are two ways to restart the whole program.
● You can use the default reset button.
● You can connect your own reset button at the pin labeled as Reset.
Arduino Uno Board General Voltage Pins
There are following output voltage pins.
● 3.3v output pin
● 5v output pin
● GND (ground)
Most of the arduino components operate at 5v or 3.3v and so can be powered with these
pins. There are several ground ports which can be used to give ground to your circuit and
components. There is a Vin pin which can be used to power the arduino uno from an
external source.
Analog I/O Pins
The Arduino uno board has 6 analog input and output pins from A0 to A5. The pins are best
used in case of the analog sensors. The analog pins can read the analog signals from them
like temperature, proximity, humidity etc and converts them into digital values that can be
read and processed by the microcontroller.
Microcontroller In Arduino Uno Board
Different Arduino boards have different microcontrollers. It can be said that is the main
component in the overall Arduino board. The main IC is a bit different in different arduino
uno boards. The microcontrollers used basically are of ATMEL Company and it is necessary
for you to know what IC you are using in order to load your program in it. You can easily read
the information on the top of the IC and select the corresponding from the option given in
the arduino software. For more information about the ic you can refer to the corresponding
datasheet.
Power Indicator LED
When you power up the Arduino uno board, there must be an LED light up which will
indicate the board is powered up correctly. In case you don’t see the glowing light, there
must be something wrong with the connection you’ve made.
TX And RX Pins
In the Arduino Uno board there are two LED’s labelled as TX (transmitter) and RX (Receiver),
Same are labelled on the pin 0 and 1 respectively. These pins are used for serial
communication and the corresponding LED glowing indicated if the data is being sent by TX
and if the data is being received by RX.
Digital I/O Pins
Arduino uno board does have 14 digital i/o pins (input/output pins) out of which contains 6
PWM output (Pulse width modulation). The digital pins can be configured to read logic
values such as 0 and 1 or can give logic (0 and 1) output for different modules such as LEDs,
Relays, etc.
Arduino- Software aspects
Although an Arduino can run as a stand-alone device once setup, it must first be
programmed by a computer.
To program the Arduino, we’ll use a software called an integrated development environment
(IDE) that’s available for free on the Arduino website.
The Arduino Integrated Development Environment - or Arduino Software (IDE) - contains a
text editor for writing code, a message area, a text console, a toolbar with buttons for
common functions and a series of menus. It connects to the Arduino hardware to upload
programs and communicate with them.
A program written in the Arduino IDE is called a ‘sketch’. A basic sketch consists of two
functions: setup() and loop(). The setup function is called first in the sketch, and is used to
create variables,to choose pin inputs and pin outputs, and to set other values needed in the
sketch. The loop function is called after the setup function, and runs repeatedly until the
board is reset or powered off. The loop function is used to do anything that happens
perpetually, such as gathering data.
Syntax rules for programming
● Every line must either end with a semicolon ‘;’ unless it’s a conditional, loop, or
function
● Comments start with a //
o Comments are text that the program ignores.
o Used to label and explain code.
Result:
Date:
Workshop practice no.
TRAFFIC SIGNAL CONTROL USING ARDUINO
Aim:
To setup a prototype of traffic signal control system using arduino
Components required:
Arduino UNO, arduino USB data cable, breadboard, connecting wires, LEDs, resistors,
Arduino IDE software
Sketch
// variables
int GREEN = 2;
int YELLOW = 3;
int RED = 4;
int DELAY_GREEN = 8000;
int DELAY_YELLOW = 1000;
int DELAY_RED = 10000;
// basic functions
void setup()
pinMode(GREEN, OUTPUT);
pinMode(YELLOW, OUTPUT);
pinMode(RED, OUTPUT);
}
void loop()
green_light();
delay(DELAY_GREEN);
yellow_light();
delay(DELAY_YELLOW);
red_light();
delay(DELAY_RED);
void green_light()
digitalWrite(GREEN, HIGH);
digitalWrite(YELLOW, LOW);
digitalWrite(RED, LOW);
void yellow_light()
digitalWrite(GREEN, LOW);
digitalWrite(YELLOW, HIGH);
digitalWrite(RED, LOW);
}
void red_light()
digitalWrite(GREEN, LOW);
digitalWrite(YELLOW, LOW);
digitalWrite(RED, HIGH);
Procedure:
1. Open arduino IDE
2. Select the port and board from tools menu
tools→board→arduino uno
tools→port→
3. Write the sketch in IDE.
4. Connect the physical setup in the breadboard
5. Compile and Upload the sketch.
Functions used in program
1. digitalWrite(pin)- Write a HIGH or LOW value to a digital pin
2. pinmode(pin)- Configure the specified pin to behave either as an input or
output.
3. delay()- Pauses the program for the amount of time (in milliseconds) specified
as parameter
Result:
Date:
Workshop practice no.
BLINK BUILT-IN LED AT A SPECIFIC INTERVAL
Aim:
To make built in LED on arduino blink at a specific intervals
Components required:
Arduino UNO board, IDE software, arduino USB data cable
Sketch:
// the setup function runs once when you press reset or power the board
void setup() {
// initialize digital pin LED_BUILTIN as an output.
pinMode(LED_BUILTIN, OUTPUT);
// the loop function runs over and over again forever
void loop() {
digitalWrite(LED_BUILTIN, HIGH); // turn the LED on (HIGH is the voltage level)
delay(5000); // wait for a second
digitalWrite(LED_BUILTIN, LOW); // turn the LED off by making the voltage LOW
delay(5000); // wait for a second
Result:
Date:
Workshop practice no.
CONTROL LED/BUZZER USING PUSH BUTTON
Aim:
To control the on/off of LED and Buzzer
Components required:
Arduino UNO board, IDE software, arduino USB data cable
Sketch:
const int BUTTON = 2;
const int LEDRed = 4;
int LEDYellow = 5;
int BUTTONstate = 0;
void setup()
pinMode(BUTTON, INPUT);
pinMode(LEDRed, OUTPUT);
pinMode(LEDYellow, OUTPUT);
void loop()
BUTTONstate = digitalRead(BUTTON);
if (BUTTONstate == HIGH)
digitalWrite(LEDRed, HIGH);
digitalWrite(LEDYellow,HIGH);
else{
digitalWrite(LEDRed, LOW);
digitalWrite(LEDYellow,LOW);
