Wireless Cranes using 8051 Project Report

7/30/2019 Wireless Cranes using 8051 Project Report

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Industrial remote bridge crane & hoist control system

CHAPTER-1

Abstract

With the advancement of technology today wireless has become a part of

mans life. The present project introduces the concept of remote bridge

cranes & hoist control through RF.

The overall system is designed with

microcontroller to make the system more effective and efficient. Utilization

of microcontroller in field of industrial bridge cranes is gaining popularity for

several reasons including price, programmability and performance

specifications offered. Software development rather than hardware

development increasingly dominates the new product design cycles.

Therefore this is one of the most common reasons as to why designers

choose microcontroller and its architecture. It also has rich and cost effective

software.

Our project mainly focuses to introduce wireless

(remote) in controlling cranes & hoist to minimize human load. The whole

project is based on Industrial remote bridge cranes and hoist control

systems. To show that the concept can be successfully implemented we

have built a prototype module.

This report goes on to explain as to how

the prototype could be developed, the working of the prototype and the logicbehind it. But, before going deep into its details we go on to explain the

overview of this project in the following paragraphs of this section.

The prototype of this project basically consists of 3 parts

1. A portable transmitter unit,

2. Receiving unit

3. Relays electrically connected to the motor

Here transmitter generates and transmits control signals. Receiving

equipment permanently installed on the crane and electrically connected to

the crane's motor controllers. A switch on the transmitter controls all

functions of the motor.

Dept. of I.T. & EPage 1


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Each switch on the remote controller generates a unique combination of

pulses that are transmitted to the crane-mounted receiver via a radio signal.

At the crane, the pulse strings are removed from the carrier signal to

activate the desired motor controllers.

The receiving equipment cabinet contains circuitry for decoding the radiosignal generated by the controller, and drivers that extract thepulse codesfrom the incoming signal and convert them into signals suitable for the

crane's motor controllers.

Radio control allows the operator to get the best line of sight possible

for operations.

Pendant control requires two persons for many lifts. Radio lets one

person do the same lifts, and do them better.

On pendant, a lot of time was wasted walking back and forth to get to

the spot where the pendant could be operated. Sometimes the

operator had to climb over stuff to hang onto the pendant. Now, the

operator has the freedom to be where best to handle the load.

On pendant, an operator was sometimes forced into awkward moves in

tight areas, even right under the load. Radio lets the operator take the

safest path on the floor.

Just having a pendant hanging down is a hazard in itself, both topersonnel and the pendant.

Crane operators are working all the time: the radio makes their job

easier. At peak periods when there are temporary workers, they can

learn radio operation much faster than pendant control.



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CHAPTER-2

INTRODUCTION:

The project report describes about design, development and fabrication of

one demonstration unit of the project work INDUSTRIAL REMOTE BRIDGE

CRANE AND HOIST CONTROL SYSTEM followed by a detailed discussion of

design consideration and design verification. The description is based on the

prototype module developed for demonstration purpose.

Crane operation has always had two simply stated objectives: get the crane

to the load, then move the load somewhere; and do it safely and efficiently.

In the past, crane movements were actuated either by a cab-mounted

operator guided by hand signals from a floor walker, or by pushbutton

pendants hanging from the crane and controlled by someone on the floor.

Today, a third method has entered the scene: remote control of a crane's

operation, particularly through radio signals, is finding more and more

popularity, because it overcomes so many of the practical problems of crane

operation and control.

Consider This: The cab-mounted operator's primary job is to move the

crane. That person may be able to work alone managing some operations

with below-the-hook attachments, such as magnets, grabs, or C-hooks. But

the vast majority of loads require assistance on the floor both for rigging and

positioning direction. Both activities slow crane movement and may involvesome safety hazards.

While pendant control solves some of these problems by

bringing crane control closer to the load, there are still problems. The

pendant is on the wrong side of the crane half the time, even with the

convenience of festooning across the bridge. Or the pendant could be

dropped from the hoist. Either way, the operator finds that dodging the

load and untangling the cable become time-consuming and somewhat

hazardous parts of the job. While a floor walker directing the operator with

hand signals or voice radio simplifies the job, crane movement would still be

slowed to the operators pace. And a walking aisle must also be available.

Most of these problems are avoided using a remote cordless

control because it permits the operator to control the crane's position from

any point on the floor that makes most sense for safety and efficiency - at



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the left of the load, on the truck, in the railcar, behind the load, or on the

rack or shelving. This makes more efficient use of both the operator's and

the crane's time.

The Remote Controller

A remote control system consists of a portable transmitter

unit that generates control signals, plus receiving

equipment permanently installed on the crane and

electrically connected to the crane's motor controllers.

Switches on the transmitter control all functions of the

crane. Installation may be as a retrofit to an existing crane,

or as part of a new construction.

Each switch on the remote controller generates a unique

combination of pulses that are transmitted to the crane-

mounted receiver via a radio signal. At the crane, the pulse strings are

removed from the carrier signal to activate the desired motor controllers.

The response time for the electronics, for all practical purposes, is

instantaneous.

The receiving equipment cabinet contains circuitry for decoding the radio

signal generated by the controller, and drivers that extract the pulse codes

from the incoming signal and convert them into signals suitable for thecrane's motor controllers

Benefits of remote cordless controls

Remote crane control may not be for every situation; the following key areas

need to be evaluated.

Duty cycle: Cranes that are in operation 20% to 80% of the time have an

inherent inefficiency in that the cab operator is idle for a great part of his

shift. By placing the person on the floor with a remote controller, he or she is

available for the other duties when the crane is in active.

Duties of floor person: If the hooking operation is relatively simple so that

one person can operate the crane with a remote controller and also handle



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the hooking, great benefits are realized. Here, too, if theduty cycle is less

than continuous, a remote control unit makes it possible for the floor person

to perform other duties between cycles.

Visibility: Can the operator see from the cab or handle rigging from the

pendant location? Are voice and hand signals needed? If so, a remote

cordless controller can improve efficiency by eliminating such

intermediaries. Crane operation will be faster, and manpower savings are

realized if a relay person/rigger can be reassigned.

Materials being handled: Are the items being moved expensive: finished

products such as steel rolls or dies? Can inaccurate hooking and spotting

damage the materials? If so, the cordless control unit will put the operator up

close where the person can be most accurate and cause least damage.

Location of cab: Must the cab be positioned in hot areas or over such

dangerous locations as soaking pits, or tilting ladles? Can the crane be

operated from a safer location? If heat is the problem, will operating the

crane from a remote location eliminate need for air conditioning?

Use of materials or machines: Are men and machines dependent upon

operation of the crane; must they frequently wait for an operator? If so, will

use of a remote controller eliminate the tie-up?



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CHAPTER-3

BLOCK DIAGRAM:

Industrial Remote Bridge Crane and Hoist Control systemhas 3 Modules Hand Held Device

Device Controller

4 channel Relay

Hand Held Device:

Hand Held Device is used to select and control the operation. Such as

Up, Down, forward and reverse. Hand Held Device transmits an encoded

data to Device Controller based on user Interface Button operations.

This module consists of the following block.

User Interface (Keypad)

RF Encoder

RF Transmitter



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Block Diagram (Hand held Remote Control):

Data Encoder:

Here the encoder is used to encode the data (Pressed Switch). This

encoded data is fed to RF Transmitter which continuously transmits thisencoded data.

RF Transmitter:

RF Transmitter sub module uses TLP434a ASK Digital Modulator. The

data stream to ASK Modulator is given using 89C52 on-chip UART operating

at a baud rate of 2400 bps.

TLP-A Series:

The "A" Series transmitter modules, based on ASK modulation, with an

output of up to 8mW depending on power supply voltage. The TLP

transmitter is based on SAW resonator and accepts both linear and digital

inputs. The transmitter TLP's output is up to 8mW with a range of


SWITCH 1

ENCODER

RF Transmitter

Module

SWITCH 2

SWITCH 3

SWITCH 4

9 Volt Battery


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approximately 400-foot (open area) outdoors. Indoors, the range is

approximately 200 foot. The TLP transmitter accepts both linear anddigital

inputs can operate from 1.5 to 12 Volts-DC, and makes building a miniature

hand-held RF transmitter very easy.

Amplitude Shift Keying

This is the type of modulation where no carrier is present in the transmission

of a zero.



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Device Controller:

Device Controller has the following Sub Modules

AT89S52 Microcontroller

RF Receiver

Output Control

Device Controller receives the encoded data from Handheld Device through

RF Receiver sub module, decodes and identifies the device to be controlled.

It uses output control sub module to control the appliances.

BLOCK DIAGRAM


RFReceiver

Decoder

Display

Microcontroller 4

Relay

s

DCMotor1

DC

Motor2


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Data Decoder:

The Data decoder is used to decode unknown noisy version of encoded data.

The encoded data is initially caught by the RF receiver. This receiver passes

on the data to decode the encoded data.

User Interface:

User Interface Module consists of 16X2 LCD and Menu Buttons.

When user presses Button, LCD shows the operation that is controlled. The

controller operations are

Moving forward

Moving reverse

Moving Up

Moving down

RF Receiver:

RF Transmitter sub module uses RLP434a ASK Digital demodulator. The

data stream from ASK demodulator.


LCD


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RLP-A Series:

The "A" Series Receiver modules are based on ASK modulation and the

receiver RLP has a sensitivity of 3uV. It operates from 4.5 to 5.5 volts-DC,

and has both linear and digital outputs. For maximum range, we recommend

antenna length to be 1/4 wave of the frequency. That means, for 433.92

MHz, the antenna length is approximately 17cm long.



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CHAPTER -4

CIRCUIT DIAGRAM & ANALYSIS:Transmitter Side:


RF

TRANSMITT

ER


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Transmitter Tools:

RF_TX_315MHz:

Features:

Complete RF Transmitter Module no external components and no tuning

required.

High Performance SAW Based Architecture with a Maximum Range of

100 feet at 4800 bps data rate.

Interface directly to Encoders and Microcontrollers with ease.

Low Power Consumption suitable for battery operated devices.

Encoder TX HT 640

Operating voltage: 2.4V~12V.

Low power and high noise immunity CMOS

Technology.

Low standby current.

Three words transmission.

Built-in oscillator needs only 5% resistor.


Label Description

DATA The Data pin of the transmitter.

VCC The power supply of the transmitter.

GND The ground of transmitter.

ANT

The hole to solder and connect

antenna. (Please select the correctantenna length, which is 24cms.)


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Easy interface with an RF or infrared transmission media.

Minimal external components

Transmitter Analysis:

The transmitter is a battery operated frequency modulation radio

transmitter. Incorporated with the transmitter is an antenna, encoder and

disposal battery. Transmitter carrier frequency is crystal controlled. When

the various switches are actuated, encoded control signals are sent to the RF

transmitter via the antenna.

Encoder:

We use 318 encoders are a series of CMOS LSIs for remote control system

applications. They are Capable of encoding 18 bits of information which

consists of N address bits & 18_N data bits.

Each address/data input is externally ternary programmable if bonded out. It

is otherwise set floating internally. The programmable address/data is

transmitted together with the header bits via an RF transmission medium

upon receipt of a trigger signal. The capability to select a TE trigger type or a

DATA trigger type further enhances the application flexibility of the 318

seriesof encoders.

Operation:

The 318 series of encoders begins a three-word transmission cycle upon

receipt of a transmission enable(TE for the HT640 active high).This cycle will

repeat itself as long as the transmission is enable (TE or D12~D17) isheld

high. Once the transmission enable falls low, the encoder output completes

its final cycle and then stops as shown below:



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Address/Data programming (Preset):

The status of each address/data pin can be individually preset to logic

high, low, or floating. If a transmission enable signal is applied, the

encoder scans and transmits the status of the 18 bits of address/data seriallyin the order A0 to AD17 for the HT640.

The address pins are usually preset to transmit data

codes with particular security codes by the DIP switches or PCB wiring, while

the data is selected using push buttons or electronic switches.

Transmissions enable: For the TE trigger type of encoders, transmission is enabled by

applying a high signal to the TE pin. But for the Data trigger type of

encoders, it is enabled by applying a high signal to one of the data pins

D12~D17.

FLOW CHART:



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Receiver side:



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Receiver tools:

Lab

el

Description

GND

The ground of transmitter.

RX Receiver connected to encoder

VCC The power supply of thetransmitter.

ANT The hole to solder and connectantenna. (Please select the correctantenna length, which is 24cms.)

Features: Low power consumption.

Easy for application.

On-Chip VCO with integrated PLL using crystal oscillator reference.

Integrated IF and data filters.

Operation temperature range: -100C ~ +600C.

Operation voltage: 5 Volts. Available frequency at: 315/434 MHz

Decoder RX HT 648L:

Operating voltage: 2.4V~12V.

Low power & high noise immunity CMOS

Technology.

8~18 address pins.

0~8 data pins.

Built-in oscillator needs only a 5% resistor.

Valid transmission indictor.

Easily interface with an RF transmission medium.



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Minimal external components.

RECEIVER ANALYSISThe receiver part is more complex then transmitter for designing the

receiver we make use of microcontroller (AT89S52) IC, decoder (HT 648) IC,

ULN 2803A & LCD display (16X2) and other passive devices.

Initially, the radio signal from the transmitter is received by the antenna

receiver data output is fed to the decoder, where it is decoded. The output of

this decoder is fed to the microcontroller (AT89S52) IC. Here we use 5 LSB

pins of I/O port 0 to interface it with decoder, while all the 8pins of I/O port 2are used to drive the relays. To display the message on the LCD (16X2) we

use the all the pins of I/O port 1 and other pins of port 3 (P3.2, P3.3, P3.4).

Decoder:

Here, we use 318 decoders as a series of CMOS LSIs. The 318 series of

decoders receives serial address and data from that series of encoders that

are transmitted by a carrier using an RF transmission medium. It then

compares the serial input data twice continuously with its local address. If no

errors or unmatched codes are encountered, the input data codes are

decoded and then transferred to the output pins. The VT pin also goes high

to indicate a valid transmission. In addition, the 318 decoders provide various

combinations of address/data number in different packages.

Operation:

The 318 series of decoders provides various combinations of address

and data pins in different packages. It is paired with the 318 series of

encoders. The decoders receive data transmitted by the encoders and

interpret the first N bits of the code period as address and the last 18N bits

as data (where N is the address code number). A signal on the DIN pin then

activates the oscillator which in turns decodes the incoming address and



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data. The decoders will check thereceived address twice continuously. If all

the received address codes match the contents of the decoders local

address, the 18N bits of data are decoded to activate the output pins, and

the VTpin is set high to indicate a valid transmission. That will last until the

address code is incorrect or no signal has beenreceived. The output of the

VT pin is high only when the transmission is valid , otherwise it is low always.

Flow Chart:

Note: The

oscillator is

disabled in the

standby state

and activated as

long as a logic

high signal is

applied to the

DIN pin. i.e., the

DIN should be

kept low if

there is no

signal input.



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Decoder Timing:

LCD INTERFACE DETAILS

INTERFACE PIN CONNECTIONS


Pin NO. Symbol Level Description1 VSS 0V Ground

2 VDD 5.0V Supply voltage for logic3 VO --- Input voltage for LCD4 RS H/L H : Data, L : Instruction code5 R/W H/L H : Read mode, L : Write mode6 E H, H L Chip enable signal7 DB0 H/L Data bit 08 DB1 H/L Data bit 19 DB2 H/L Data bit 2

10 DB3 H/L Data bit 311 DB4 H/L Data bit 412 DB5 H/L Data bit 513 DB6 H/L Data bit 614 DB7 H/L Data bit 715 A --- Backlight anode16 K --- Backlight cathode


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CONNECTION DETAILS:

In our applications we generally use the LCD only as a display (output)

device even though we have an option of both write on and read from theLCD module. So we usually connect the R/W pin to Ground and use just towrite and display what we want. Here we generally use 16 x 2 matrix LCD.There are 2 registers inside the LCD, Command Register and DATA register.

The RS pin is used to select these registers. To select command register

make RS = 0 and 1 to select DATA register. Command register is used to tell

the LCD to start the display from a certain location, to clear or to perform

any other operation.

When we want to display a character or any numberwe should select the DATA register a write into it to display.

STEPS:

For sending Command to the LCD

Write the command code on the DATA lines of the LCD

Make the RS pin LOW to select Command Register

Send a High-to-low pulse to the Enable pin to enable the selection theCommand register

Give little delay and repeat the process to send the next command to

the LCD.



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For displaying a data on LCD:

Write the data to be displayed on the DATA lines of the LCD

Make the RS pin HIGH to select DATA Register

Send a High-to-low pulse to the Enable pin to enable the selection of

the DATA register

Give little delay and repeat the process to Display the next data.

Relays:

A relay is a simple electromechanical switch made up of an electromagnet

and a set of contacts relays are found hidden in all sorts of devices. In fact,some of the first computer ever built used relays to implement Boolean

gates.

Relay Construction:

Relays are amazingly simple device. There are four parts in every relay:

Electromagnetic.

Armature that can be attracted by the electromagnet.

Spring.

Set of electrical contacts.

The following figure shows these four parts in action



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In this figure, we can see that a relay consists of two separate and

completely independent circuits. The first is at the bottom and drives the

electromagnet. In this circuit, a switch is a controlling power to the armature

(BLUE).The armature is acting as a switch in the second circuit and light is

on. When the electromagnet is not energized, the spring pulls the armature

away and the circuit is not complete. In that case, the light is dark. Relays

can be used to implement Boolean logic.

When we purchase relays, we generally have control over several variables:

The voltage and current that is needed to activate the armature.

The voltage and current that can run through the armature and thearmature contacts.

The number of armatures (generally one or two).

The number of contacts for the armature (generally one or two the

relay shown here has two, one of which is unused).

Whether the contact (if only one contact is provided) is normally open

(NO) or normally closed (NC).



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Relays Applications:

In general, the point of a relay is to use small amount of power in the

electromagnet coming, say, from a dash board switch or a low power

electronic circuit to move an armature that is able to switch a much larger

amount of power. For example, we might want the electromagnet to

energize using 5 volts and 50mili amps (250miliwatts), while the armature

can support 120 volts AC at 2 Amps (240 Watts).

Relays are quite common in home appliances where there is an electronic

control tuning on something like a motor or a light. These are also common

in cars, where the 12v supply voltage means that just about everything

needs a large amount current.

In later model cars, manufactures have started combining relay panels in to

the fuse box to make maintenance easier.

In place where a large amount of power needs to be switched, relays are

often cascaded. In this case a small relay switches the power needed to drive

a much larger relay, and that second relay switches the power to drive the

load.

Power Supply

MC78XX/LM78XX/MC78XXA 3-Terminal 1A Positive Voltage

Regulator

Features:

Output Current up to 1A.

Output Voltages of 5, 6, 8, 9, 10, 12, 15, 18, 24V.



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Thermal Overload Protection.

Short Circuit Protection.

Output Transistor Safe Operating Area Protection

Description:

The MC78XX/LM78XX/MC78XXA series of three terminal positive regulators

are available in the TO-220/D-PAK package and with several fixed output

voltages, making them useful in a wide range of applications.

Each type employs internal current limiting, thermal shut down and safe

operating area protection, making it essentially indestructible. If adequate

heat sinking is provided, they can deliver over 1A output current. Although

designed primarily as fixed voltage regulators, these devices can be used

with external components to obtain adjustable voltages and currents.



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ELECTRICAL CHARACTERISTICS (MC 7805/LM 7805):

MICROCONTROLLER (ATMEL AT89S52):

FEATURES

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



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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

ATMEL Description

The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller

with 8 Kbytes of in-system programmable Flash memory. The device is

manufactured using Atmels high-density nonvolatile memory technology

and is compatible with the industry-standard 80C51 instruction set and pinout. The on-chip Flash allows the program memory to be reprogrammed in-

system or by a conventional nonvolatile memory programmer. By combining

a versatile 8-bit CPU with in-system programmable Flash on a monolithic

chip, the Atmel AT89S52 is a powerful microcontroller which provides a

highly-flexible and cost-effective solution to many embedded control

applications. The AT89S52 provides the following standard features: 8K bytes



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of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog timer, two data pointers,

three 16-bit timer/counters, a six-vector two-level interrupt architecture, a

full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the

AT89S52 is designed with static logic for operation down to zero frequency

and supports two software selectable power saving modes. The Idle Mode

stops the CPU while allowing the RAM, timer/counters, serial port, andinterrupt system to continue functioning. The Power-down mode saves the

RAM contents but freezes the oscillator, disabling all other chip functions

until the next interrupt or hardware reset.

CHAPTER -5

Radio frequency:

Radio frequency (RF) is a frequency or rate ofoscillation within the range

of about 3 Hz to 300 GHz. This range corresponds to frequency of

alternating electrical signals used to produce and detect radio waves. Since

most of this range is beyond the vibration rate that most mechanical

systems can respond to, RF usually refers to oscillations in electrical circuits.

Special properties of RF electrical signals:

Electrical currents that oscillate at RF have special properties not shared

by direct current signals. One such property is the ease with which they can

ionize air to create a conductive path through air.

This property is exploited by 'high frequency' units used in electric arc

welding, although strictly speaking these machines do not typically employ

frequencies within the HF band. Another special property is an

electromagnetic force that drives the RF current to the surface of

conductors, known as the skin effect. Another property is the ability to

appear to flow through paths that contain insulating material, like

http://en.wikipedia.org/wiki/Frequencyhttp://en.wikipedia.org/wiki/Oscillationhttp://en.wikipedia.org/wiki/Hzhttp://en.wikipedia.org/wiki/Electrical_signalhttp://en.wikipedia.org/wiki/Radio_waveshttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Arc_weldinghttp://en.wikipedia.org/wiki/Arc_weldinghttp://en.wikipedia.org/wiki/Skin_effecthttp://en.wikipedia.org/wiki/Frequencyhttp://en.wikipedia.org/wiki/Oscillationhttp://en.wikipedia.org/wiki/Hzhttp://en.wikipedia.org/wiki/Electrical_signalhttp://en.wikipedia.org/wiki/Radio_waveshttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Arc_weldinghttp://en.wikipedia.org/wiki/Arc_weldinghttp://en.wikipedia.org/wiki/Skin_effect


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the dielectric insulator of a capacitor. The degree of effect of these

properties depends on the frequency of the signals.

Frequencies:

http://en.wikipedia.org/wiki/Dielectrichttp://en.wikipedia.org/wiki/Dielectric


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Name Symbo

l

Frequency Waveleng

th

Applications

Extreme

ly low

frequen

cy

ELF 330 Hz10100 M

m

Directly audible when converted

to sound (above

~20 Hz), communication with

submarines

Super

low

frequen

cy

SLF 30300 Hz 110 MmDirectly audible when converted to

sound, AC power grids (5060 Hz)

Ultra

low

frequen

cy

ULF3003000 H

z

1001000

km

Directly audible when converted to

sound, communication with mines

Very

low

frequen

cy

VLF 330 kHz10100 k

m

Directly audible when converted to

sound (below ~20 kHz;

or ultrasound otherwise)

Low

frequen

cy

LF 30300 kHz 110 kmAM broadcasting, navigational

beacons, amateur radio

Medium

frequen

cy

MF3003000 k

Hz

1001000

m

Navigational beacons, AM

broadcasting, amateur radio,

maritime and aviation

communication

High

frequen

cy

HF 330 MHz 10100 mShortwave, amateur radio, citizens'

band radio, skywave propagation

Veryhigh

frequen

cy

VHF 30300 MHz 110 mFM broadcasting, amateur

radio, broadcast

television, aviation, GPR, MRI

Ultra

high

frequen

cy

UHF3003000 M

Hz

10100 c

m

Broadcast television, amateur

radio, mobile telephones, telephones,

wireless, remote keyless entry for

automobiles, microwave ovens, GPR

Superhigh

SHF 330 GHz 110 cm

Wireless networking, satellite

links, amateur radio, microwave links,
http://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Soundhttp://en.wikipedia.org/wiki/Communication_with_submarineshttp://en.wikipedia.org/wiki/Communication_with_submarineshttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Electric_power_transmissionhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Mininghttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Ultrasoundhttp://en.wikipedia.org/wiki/AM_broadcastinghttp://en.wikipedia.org/wiki/Non-directional_beaconhttp://en.wikipedia.org/wiki/Non-directional_beaconhttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Medium_frequencyhttp://en.wikipedia.org/wiki/Medium_frequencyhttp://en.wikipedia.org/wiki/Medium_frequencyhttp://en.wikipedia.org/wiki/AM_broadcastinghttp://en.wikipedia.org/wiki/AM_broadcastinghttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/High_frequencyhttp://en.wikipedia.org/wiki/High_frequencyhttp://en.wikipedia.org/wiki/High_frequencyhttp://en.wikipedia.org/wiki/Shortwavehttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Citizens'_band_radiohttp://en.wikipedia.org/wiki/Citizens'_band_radiohttp://en.wikipedia.org/w/index.php?title=Skywave_propagation&action=edit&redlink=1http://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/FM_broadcastinghttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Broadcast_televisionhttp://en.wikipedia.org/wiki/Broadcast_televisionhttp://en.wikipedia.org/wiki/Airbandhttp://en.wikipedia.org/wiki/Ground-penetrating_radarhttp://en.wikipedia.org/wiki/MRIhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Mobile_telephoneshttp://en.wikipedia.org/wiki/Remote_keyless_entryhttp://en.wikipedia.org/wiki/Microwave_ovenhttp://en.wikipedia.org/wiki/Super_high_frequencyhttp://en.wikipedia.org/wiki/Super_high_frequencyhttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Extremely_low_frequencyhttp://en.wikipedia.org/wiki/Soundhttp://en.wikipedia.org/wiki/Communication_with_submarineshttp://en.wikipedia.org/wiki/Communication_with_submarineshttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Super_low_frequencyhttp://en.wikipedia.org/wiki/Electric_power_transmissionhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Ultra_low_frequencyhttp://en.wikipedia.org/wiki/Mininghttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Very_low_frequencyhttp://en.wikipedia.org/wiki/Ultrasoundhttp://en.wikipedia.org/wiki/AM_broadcastinghttp://en.wikipedia.org/wiki/Non-directional_beaconhttp://en.wikipedia.org/wiki/Non-directional_beaconhttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Medium_frequencyhttp://en.wikipedia.org/wiki/Medium_frequencyhttp://en.wikipedia.org/wiki/Medium_frequencyhttp://en.wikipedia.org/wiki/AM_broadcastinghttp://en.wikipedia.org/wiki/AM_broadcastinghttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/High_frequencyhttp://en.wikipedia.org/wiki/High_frequencyhttp://en.wikipedia.org/wiki/High_frequencyhttp://en.wikipedia.org/wiki/Shortwavehttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Citizens'_band_radiohttp://en.wikipedia.org/wiki/Citizens'_band_radiohttp://en.wikipedia.org/w/index.php?title=Skywave_propagation&action=edit&redlink=1http://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/Very_high_frequencyhttp://en.wikipedia.org/wiki/FM_broadcastinghttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Broadcast_televisionhttp://en.wikipedia.org/wiki/Broadcast_televisionhttp://en.wikipedia.org/wiki/Airbandhttp://en.wikipedia.org/wiki/Ground-penetrating_radarhttp://en.wikipedia.org/wiki/MRIhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Ultra_high_frequencyhttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Mobile_telephoneshttp://en.wikipedia.org/wiki/Remote_keyless_entryhttp://en.wikipedia.org/wiki/Microwave_ovenhttp://en.wikipedia.org/wiki/Super_high_frequencyhttp://en.wikipedia.org/wiki/Super_high_frequencyhttp://en.wikipedia.org/wiki/Amateur_radio


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ISM (Industrial, Scientific and Medical) Bands:

The industrial, scientific and medical (ISM)radio bands were originally

reserved internationally for the use of RF electromagnetic fields for

industrial, scientific and medical purposes other than communications. In

general, communications equipment must accept any interference

generated by ISM equipment. Communication devices using the ISM bands

must tolerate any interference from ISM equipment; these bands are

typically given over to uses intended for unlicensed operation, since

unlicensed operation typically needs to be tolerant of interference from other

devices anyway.

For many people, the most commonly encountered ISM device is the home

microwave oven operating at 2.45 GHz. However, in recent years these

bands have also been shared with license-free error-tolerant communications

applications such as wireless LANs and cordless phones in the 915 MHz,

2450 MHz, and 5800 MHz bands. Because unlicensed devices already are

required to be tolerant of ISM emissions in these bands, unlicensed low

power uses are generally able to operate in these bands without causing

problems for ISM users.The ISM band is also widely used for Radio-frequencyidentification (RFID) applications with the most commonly used band being

the 13.56 MHz band.

Several brands of radio control equipment use the 2.4 GHz band range for

low power remote control of toys, from gas powered cars to miniature

aircraft. Worldwide Digital Cordless Telecommunications or WDCT is an ISM

band technology that uses the 2.4GHz radio spectrum. In our project module

we used ISM band frequency 433/315MHz.

http://en.wikipedia.org/wiki/Microwavehttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Security_scanhttp://en.wikipedia.org/wiki/Extremely_high_frequencyhttp://en.wikipedia.org/wiki/Security_scanhttp://en.wikipedia.org/wiki/Security_scanhttp://en.wikipedia.org/wiki/Radio_bandhttp://en.wikipedia.org/wiki/Microwave_ovenhttp://en.wikipedia.org/wiki/Wireless_LANhttp://en.wikipedia.org/wiki/Cordless_telephonehttp://en.wikipedia.org/wiki/Radio-frequency_identificationhttp://en.wikipedia.org/wiki/Radio-frequency_identificationhttp://en.wikipedia.org/wiki/Radio-frequency_identificationhttp://en.wikipedia.org/wiki/Extremely_high_frequencyhttp://en.wikipedia.org/wiki/Microwavehttp://en.wikipedia.org/wiki/Amateur_radiohttp://en.wikipedia.org/wiki/Security_scanhttp://en.wikipedia.org/wiki/Radio_bandhttp://en.wikipedia.org/wiki/Microwave_ovenhttp://en.wikipedia.org/wiki/Wireless_LANhttp://en.wikipedia.org/wiki/Cordless_telephonehttp://en.wikipedia.org/wiki/Radio-frequency_identificationhttp://en.wikipedia.org/wiki/Radio-frequency_identification


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CHAPTER-6

SOURCE CODE:

ORG 0000H;

MOV P2,#0; initial turn off relay

CALL LCD_INI;

MAIN: MOV A,#01H;

ACALL COMMAND;

CALL DELAY;

CALL NAM1;

MOV A,#0C0H;

ACALL COMMAND;

CALL DELAY;

CALL NAM2;

MOV P0,#0FFH;

JNB VT,$;

CALL DELAY;

JB P0.0,FORWARD MOTORING;

JB P0.1,REVERSE MOTORING;

JB P0.2,UP MOTORING;

JB P0.3,DOWN MOTORING;



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CLRSCR;

JMP MAIN;

FORWARD MOTORING:SETB P2.0;

CALL DISP1;

CLR P2.O;

CALL DELAY;

JMP MAIN;

REVERSE MOTORING: SETB P2.1;

SETB P2.1;

CALL LCD2;

CLR P2.1;

CALL DELAY;

JMP MAIN

UP MOTORING: SETB P2.2;

SETB P2.2;

CALL LCD3;

CLR P2.2;

CALL DELAY;

JMP MAIN;

DOWN MOTORING: SETB P2.3;

SETB P2.3;



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CALL LCD4;

CALL DELAY

CLR P2.3;

CALL DELAY;

JMP MAIN;

DISP 1: MOV A,#80H;

ACALL COMMAND;

ACALL LCD1;

RET;

LCD_INI :MOV A,#38H;

ACALL COMMAND;

MOV A,#0EH;

ACALL COMMAND;

MOV A,#01H;

ACALL COMMAND;

MOV A,#06H;

ACALL COMMAND;

MOV A,#80H;

ACALL COMMAND;

RET;

NAM1: MOV R1,#16;



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MOV DPTR,#NAME1;

UP0: CLR A;

MOVC A,@A+DPTR;

CALL DISP;

INC DPTR;

DJNZ R1,UP0;

RET

NAM2: MOV R1,#16;

MOV DPTR,#NAME2;

UP01: CLR A;

MOVC A,@A+DPTR;

CALL DISP;

INC DPTR;

DJNZ R1,UP01;

RET

LCD1: MOV A,#01H;

ACALL COMMAND;

MOV R1,#16;

MOV DPTR,#MSG1;

UP: CLR A;

MOVC A,@A+DPTR;



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CALL DISP;

INC DPTR;

DJNZ R1,UP;

RET

LCD2: MOV A,#01H;

ACALL COMMAND;

MOV R1,#16;

MOV DPTR,#MSG2;

UP1: CLR A ;

MOVC A,@A+DPTR;

CALL DISP;

INC DPTR;

DJNZ R1,UP1;

RET

LCD3: MOV A,#01H;

ACALL COMMAND;

MOV R1,#16;

MOV DPTR,#MSG3

UP2: CLR A;

MOVC A,@A+DPTR;

CALL DISP;



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INC DPTR;

DJNZ R1,UP2;

RET

LCD4: MOV A,#01H;

ACALL COMMAND;

MOV R1,#16;

MOV DPTR,#MSG4;

UP3: CLR A;

MOVC A,@A+DPTR;

CALL DISP;

INC DPTR;

DJNZ R1,UP3;

RET

COMMAND: ACALL READY;

MOV P1,A;

CLR P3.5;

CLR P2.6;

SETB P3.4;

CLR P3.4;

CALL DELAY

RET



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DISP: ACALL READY;

MOV P1,A;

SETB P3.5;

CLR P2.6;

SETB P3.4;

CLR P3.4;

RET

READY: CALL DELAY;

RET

DELAY: MOV 70H,#250;

MOV 71H,#255;

DJNZ 71H,$ ;

RET

CLRSCR: MOV A,#01H;

ACALL COMMAND;

RET

NAME2: db"CONTROL PANEL"

NAME1: db"CRANE & HOIST "

MSG1: db" MOVING RIGHT

MSG2: db" MOVING LEFT"

MSG3: db" MOVING UP"



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MSG4: db" MOVING DOWN ";

END;



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CHAPTER-7

Hardware Details:The ICs and other important components used in this project work procured

from CRANES SOFTWARE LIMITED BANGALURU. The details or the data

sheets of the ICs are downloaded from internet the following are the

websites that can be browsed for collecting the data sheets.

1. www.sunrom.com

2. www.holtek.com.tw

3. www.maxim-ic.com

4. www.alldatasheet.com

5. www.datasheets4u.com

6.www.fairchildsemi.com

The following are the ICs and other important components used in this

project work.

1. AT89S52 microcontroller IC.

2. ULN 2809A.IC.

3. Encoder TX-HT640.

4. Decoder RX-HT648L.

5. RF Transmitter & Receiver.

6. Voltage Regulator.

7. Relays.

http://www.holtek.com.tw/http://www.fairchildsemi.com/http://www.holtek.com.tw/http://www.fairchildsemi.com/


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CHAPTER-8

Applications:

This mainly industrial-related area is where best known for its technological

excellence leading to many exciting applications where productivity, safety

and economy all have been improved. Following are some applications.

1. PINPOINT PRECISION THROUGH STEPLESS CONTROL

ACHIEVED BY HEAVY EQUIPMENT MANUFACTURER

The benefits of radio remote control are evident not just in terms of speedand accuracy but also in terms of load-handling accuracy. One major

manufacturer of heavy construction equipment recently took advantage of

this feature by adapting two of its cranes to stepless control, then upgrading

the radio remote to the 10k series.

The controls on the

two 80-foot-span cranes make it possible to swiftly and safely maneuver

large engine assemblies into and out of tightly confined noise suppressing

test cells.

Operators find the transmitter to be comfortable, familiar and compatible

with their earlier radio remote systems. Thanks to the dynamic braking

afforded by the stepless motor controls, they also report fewer maintenance

problems. Enclosed in a lightweight aluminum case with concealed antenna,

the transmitter may be powered by either disposable battery packs or

rechargeable cells.

2. TIME MULTIPLE SHARED TECHNOLOGY HELPS

CONTROL OVER 100 CRANES AT AIRCRAFT PLANT



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At a major aircraft manufacturers plant, over 100 cranes operate on radio

control without cross-interference, thanks to Time Multiple Shared (TMS)

technology. The result is increased throughput and flexibility in production,

painting, curing and transfer of parts to the kitting building.

Three or four collocated remote radio control systems time share a

single radio frequency channel. This means that in a single facility, the

company can operate more than 100 control receivers with fewer than 50

transmitters on only 11 radio frequencies.

The heart of the system is software based on both "random" and

"demand" time division multiplexing techniques. Security of the system rests

in the use of unique crane bridge and hoist code plugs for initiating

transmitter control. First-come, first-serve protocol prevents two or more

transmitters with identical code plugs from controlling the master receiver.

3. ANTI-COLLISION SYSTEMS WILL PREVENT MISHAPS

WITH OTHER PLANT MACHINERY

When a machine tool manufacturer learned that a collision in anothercompanys plant between an overhead crane and a piece of equipment

had caused $300,000 of damage, it determined to take precautionary

action. Thanks to the installation of an anti-collision system, the plant

avoided the threat effectively and economically. The obstruction in the

plant was a machining mill column.

In its upward position it extends directly into the travel path of two 77

foot-span overhead cranes. By equipping the machining mill with a low-

frequency transmitter, it can signal its presence to the cranes. For their part,

the cranes slow down and stop before impact but can move off in the reverse

direction at full speed.



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More conventionally, Laser Anti-Collision devices by Berlet are used for

preventing cranes from colliding with each other. Cranes themselves can be

operated with any one of the Berlet K series radio control devices

independent of the anti-collision system.

4. RADIO CONTROL IS KEY TO EFFICIENCY IN BLANKING,

STAMPING OPERATIONS

Radio control as opposed to conventional cab or pendant control is essential

to the efficient and highly productive operations of blanking and stamping

areas in plants, especially automotive plants. Todays plants all run on a just-

in-time system so cranes must become an integral part of the process.

In stamping, for example, quality control and subsequent positioning may be

performed by an operator as he/she handles the coil in the course of running

the crane by radio. Thats where the flexibility of Berlet radio control helps

the operator perform several functions sequentially and even

simultaneously.

At one Chrysler automotive plant, series 10-K remote radio-control systemsdirect cranes in the performance of material handling, tooling changes and

maintenance procedures that relate to die sets and bolsters.

A typical die change takes less than 10 minutes, thanks to the cranes. Radio

control gives the operator the flexibility to quickly place the die sets and to

service the bolster (which holds the dies) on either side of the transfer press.

It would have been virtually impossible to service both sides with pendant

control.

The die maintenance crane is also used on a continual basis, under radio

remote control. It handles dies in the wash area, opening and turning them



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90 degrees while they are steam cleaned. The heaviest dies weigh around 15

tons.

5. CONTROLLED RANGE PLUS AT AUTO PLANT DETECTS,

IGNORES EXTRANEOUS SIGNALS

An automotive stamping plant demands constant worker attention to safety

procedures. It runs round the clock and requires continuous movement of

large heavy metal dies into and out of high-speed presses where fenders,

door panels, hoods, bumpers and many other parts are formed and stamped.

At one Ford plant overhead cranes are used exclusively to perform these

tasks, all under radio remote control. Many of them have double hoists with

lift capacities to 50 tons. To maintain an excellent safety record, the plant

has also installed Controlled Range Plus.

This circle of safety automatically prevents the operator from

controlling the crane beyond a pre-determined safe distance from the load. A

problem, however, was that powerful harmonics from an electronic discharge

machine (EDM) had the potential to cause interference.

The threat was solved by the use of the Controlled Range Plus auto

bypass option. It recognizes the harmonics and automatically permits normal

crane operation regardless.

6. EXPERIMENT WITH RADIO REMOTE CONTROL MAKES

THIS PAPER MAKER A TRUE BELIEVER.

One paper maker retrofitted two overhead bridge cranes with Series 8-

K radio remote controls as an experiment. A few years later it installed the

technology on eight new cranes in a major expansion project involving two

plants.



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The eight cranes consist of three 50-ton process cranes on runways up

to 480 feet long and 92 feet wide, and five maintenance cranes for

maneuvering equipment during shutdowns.

Radio control allows the operator to get the best line of sight possible

for both kinds of operations. It is particularly important at a rewind station

(where big rolls are rewound into smaller rolls) because loads are then

transported to several different pieces of equipment located at different

levels, including a mezzanine. The papermaker says that now it is familiar with

radio-control operation, it will install the technology on all new cranes.

7.RADIO REMOTE CONTROL A NATURAL CHOICE FOR

STEEL SERVICE CENTERS

When you see operators clambering over piles of steel trying to manipulate

both loads and a heavy crane pendant, you know there must be an easier

way! The easier way is with Berlet radio remote control, especially a system

such as the 10-K with its lightweight transmitter that may even be carried

around on a belt or in its own belly pack.

At one large industrial service center where they move tons and tons of

plate, bar, coil, pipes and more, the 10-K system makes light of overhead

handling by many of the more than 70 overhead cranes. The transmitter

weighs under two pounds and the crane-mounted receiver itself is just 18"

by 18" by 7". Despite its small size, the transmitter is extremely rugged and

easily withstands constant use and being dropped a couple 0f times a day.

The 10-K system can be set up in as little as 3 hours. It can be quickly

programmed in the field for most hoist control speeds simply by flipping a

dip switch in the transmitter. The steel service center also makes use of the

Time Multiple Sharing system to control up to four cranes on a single

frequency.



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8. STRUCTURAL STEEL COMPANY MAKES BIG BOOST IN

HANDLING EFFICIENCY

A structural steel company reports a 40% increase in shop productivity by

switching from wired pendant control of a 5-ton under hung crane to radio

remote control. The radio replaces a bulky pendant and cord with a

lightweight, hand-held transmitter.

The plant uses a dog (beam clamp) to pick up beams up to 60 feet long, a

job which used to take two persons to balance the beams on pendant. Now,

one person can do the job more efficiently.

Other times, on pendant, when the crane was operated by a single operator,

there were times when he had to walk all the way round the 60-foot beam to

facilitate placement of the load.

Also, the operator used to be confined to a position near the load: now that

person has the freedom to operate the crane from the best and safest

position.

9.MINING EQUIPMENT MANUFACTURER USES RADIO

REMOTE THROUGHOUT

A major manufacturer of mineral processing equipment for

international mining sites now uses radio remote control for every crane in

its 200,000-square foot facility, from raw materials handling to truck loading

for shipment to the customer. The manufacturer has progressed from the

Berlet Series 8-K to the Series 10K with Time Multiple Sharing (TMS).

This technology permits control of up to 4 cranes on a single frequency, and

allows many different ones to operate in close quarters without cross-

interface



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Manufacturing begins with punching, cutting, drilling and welding. During

each step radio remote control is used for the precise movement of parts.

There are no crane operators as such: everyone is a crane operator.

Whenever workers need a crane movement, they get the hand-held control

and do it themselves its that simple.

The technology has made a big impact in the machine shop too. Large pieces

of plate and bar steel must be positioned onto lathes and machining centers.

Radio control accomplishes this more efficiently and safely because

operators dont have to worry about where the pendant wire is located when

loading a machine. They also have more control over the part.

Plant management is very satisfied with the reliability and durability of the

technology, including the hand-held controllers, which have stood up to

heavy-duty use even better than expected. Laser anti-collision technology is

also under consideration for the plant.

10. ANTI-COLLISION DEVICES WORK FOR STACKER

CRANES AS WELL

Some automated storage systems call for more than one stacker

crane to operate in an aisle, which demands foolproof anti-collision methods.

Berlet makes this possible through the application of 14-K Laser Anti-

Collision technology.

One food manufacturer uses the technology to ensure manned stacker

cranes dont collide in 420 foot-long aisles where they travel at speeds to

525 fpm. The transmitter on each crane sends a signal to any other in the

same aisle. Three separate output relays are wired to override the onboard

directional and speed controls, one for each predetermined set distance.



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At the furthest distance (100 feet) the Anti-Collision technology sounds

a warning alarm. At the middle distance, the technology automatically slows

the crane down. At the nearest distance (10 feet), it brings the crane to a

halt, using the cranes installed electric brakes.

The technology can be installed on any number of cranes without

cross-interference and includes built-in monitoring and an alarm in case of

internal failure. It requires minimal maintenance.

11. OUTBOARD MOTOR PLANT FINDS SUCCESS IN

HOISTING PROCESS

A plant that finishes outboard motor engine castings and fits them with

components now use 10-K series for overhead hoists in the process.

One of the functions at the plant is to treat the castings via an 11-stage

conversion and coating process, where an Allen Bradley PLC (programmable

logic controller) controls a 700 foot-long closed-loop monorail.

The monorail is equipped with 10 Electro Lift Hoists mounted on a track 12

feet above the plant floor. They were originally fitted with pendant controls

to facilitate overriding of the PLC for loading, unloading or bypassing one of

the conversion stages. It was an awkward operation that included the need

to hook the pendant down with an 8-foot metal rod.

Now, all 10 of the hoists are controlled by a single Series 10-K transmitter.

By using the 10-Ks thumb-wheel switches, an operator can dial up any

individual hoist.

Once a hoist is selected, the operator removes it from PLC control via a

manual toggle switch, then lowers or raises it with the down or up toggle



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switch. The hoist is then returned to PLC control. Up to 1000 hoists could be

controlled this way using Berlet technology.

12. LABOR EFFICIENCY GETS BIG BOOST AT PAPER

MANUFACTURERS PLANT

When the rolls on a paper-making machine needed to be lifted several times

a day for repairs, this manufacturer relied on a 35-ton overhead cab-

controlled crane, with one operator aloft and two on the ground giving

directions.

Conditions at the plant are not pleasant 40 feet

up because steam from the paper drying process raises the temperature

there up to 43C (110F). The company decided to switch to a radio remote

control system to utilize man power better and improve working conditions.

A number of safety features are incorporated in the system. A

warning alarm on the crane can be activated if necessary to warn workers of

crane motion. Crane power can be tuned on only after six conditions are met

by the radios microcomputer that safe reliable communications have beenestablished.

The radio remote system reduces crewing

requirements from three to two persons per crane, and uncomfortable crane

cab conditions leading to lost work time are a thing of the past. Installation of

the entire system took less than two days.



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CHAPTER-9

References:

The following are the references made during the development of this project

work.

1. Geial.E.Williams,practical transistor circuit design and analysis, Tata Mc

Graw Hill, 1996, ISBN 0-07-099672-5.

2. K.R Brothker,Integrated Circuits, Khannan Publications, 1996.

Manuals:

1. Advanced CMOS Logic Data Book, Texas Instruments.

2. Modern IC Data & Substitution manual, 1998 ISBN 81-7029-943-8.

Following are the sites that have been browsed for collecting literature

1. www.atmel.com

2. www.wikipedia.org

3. www.howstuffswork.com

4. www.electronicsforu.com

5. www.texasinstruments.com

6. www.nseelectronics.com

http://www.electronicsforu.com/http://www.texasinstruments.com/http://www.nseelectronics.com/http://www.electronicsforu.com/http://www.texasinstruments.com/http://www.nseelectronics.com/


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Wireless Cranes using 8051 Project Report

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