WEEK 7

Date:  17  - 21 March 2014

Subject : Program testing by using PC-W compiler.

Introduction: The program need to build and compiled by using a software to detect an error obtained. 

Objectives: 

1. To test or compile the program using software.
2. To simulate the program and test using proteus software.

Project Description:

1.  This machine was controlled by PIC circuit. So, it have a program that burned into IC and it will control the output of the machine. 

2.  The program need to compiled or simulate to check iether it have an error obtained or not. If there have an error so I need to recheck the program to troubleshoot where is the error coming from. 

Figure 1: The PCW compiler software

3.  From figure 1, it is the PCW compiler that used to simulate the programming used for PIC 16F8777A.

Figure 2: The output result after compile process

4.  From figure 2, it shows that there is non error was obtained from my program. So, this program can be burned into IC using PIC burner. Below is some view of my program that have been used in this project.

Figure 2: Some program that have been used for this project

5.  Problem have obtained when used the other version of compiler known as MpLab software. It have produced one error whic is the PIC is not have in the directory.

Figure 3: Error obtained when using MpLab software

Problem Encountered:
 
There have no error obtained from PCW compiler but when using MpLab software it have produced much error at the simulation output. This might because of the program is not compatible with the MpLab version. Some include or default setting from this programmed is not matched with the software. Figure 3 shows the problem obtained.

 
Project Outcome:

Some knowledge have been obtained from this task which is I have learned how to used this software. Hence, my research project is on schedule and I should encounter no problems finishing it.  

WEEK 6

Date:  10  - 14 March 2014

Subject : Body compartment installation

Introduction: Body compartment of this machine is to put the PIC circuit, blade motor, gearbox motor and 360 degree wheel. 

Objectives: 

1. To put all circuit and other material into body compartment
2. To make the grass cutter machine into based on the design illustration.

Project Description:

1.  Body compartment for this project is made from prospect. Bottom prospect is the part to put all materials such as motor and circuit.

Figure 1: The installation of the gearbox motor to the prospect

2.  Each material need to install part by part. First is the installation of the PIC circuit. Figure 2 shows the connector to put the PIC circuit on the prospect. The hole need to drill for include the wire from gearbox motor to the circuit.

Figure 2: The hole process for the PIC circuit connector

3.  The blade motor is from Mabuchi manufacturer with input voltage of 6V. The motor need to put at the center of the prospect for the blade grass cutting as shown in figure 3. 

Figure 3: The installation of blade motor

4.  Figure 4 shows the location of gearbox motor on the prospect with the 4 wire to the PIC circuit.It is to move the machine forward or reverse direction.

Figure 4: The wire from gearbox motor is connected to the IC motor driver

Figure 5: The PIC circuit is set on the prospect

5.  The use of LED is act as an indicator for power supply, the direction of motor either forward or reverse and relay circuit. there have 5 LED in this circuit. Below is the installation of the LED and the connector for the 9V and 1.5V battery snap.

Figure 6: LED for power supply and relay indicator

Figure 7: The completely all materials on the prospect

6.  Above shows the completely location for all materials for this machine. It is quite compared and it might make this machine so heavy.

Problem Encountered:
 
There have a few minor problems during this task which is difficult to set the location of direction and blade motor. It also need to make a hole process for wire from the motor to the circuit.

 
Project Outcome:

Many input have been learned from this process. I have to imagine where is the exactly location for each materials used for this machine. Hence, my research project is on schedule and I should encounter no problems finishing it.  

WEEK 5

Date:  3  - 7 March 2014

Subject :Double gear box installation (Tamiya Manufacturer)

Introduction: This types of motor need to install manually by following to the attachment sheet at the box. It is for make the machine move forward or reverse task. 

Objectives: 

1. To do an installation for double gear box motor.
2. To set the suitable various of gear ratio for this types of motor.

Project Description:

1. The Tamiya double gearbox is a compact unit with two independent motors and gear trains. The kit includes two motors and all gears and parts to build any of the four possible gear ratio configurations (12.7:1, 38:1, 115:1, and 344:1). Although it is not typical, it is possible to assemble each side with different gear ratios. There are two possible output axle locations (for any given gear ratio, only one output location is possible).

Figure 1: The material have in the packaging box

 

Comparison to the Tamiya twin-motor gearbox

The double gearbox is very similar to the Tamiya 70097 twin-motor gearbox, as shown in the picture to the right. The gear ratio options of the two products complement each other well, but the mounting holes and overall dimensions vary slightly. The double gearbox is shorter and wider than the twin-motor gearbox, and the gears are a bit smaller and wider. This should make the double gearbox a bit more robust, though we have not heard any reports of the twin-motor gearbox gears breaking.

Figure 2: Comparison between double and twin gear box

2.  From figure 3, it can see there have 4 types of ratio with different characteristics of torque and speed rotation. for this project, I have used type D because this is machine is heavy. So it is need more torque to move this machine forward or reverse. 

Figure 3: The different ratio for double gear box motor

3.  It already have the step for do the motor installation. Below is the picture about the progress of installation of DC gearbox motor.

Figure 4: Body compartment of the motor

Figure 5: Installation of the gear of the motor

Figure 6: The gear installation for the motor 1

Figure 7: The complete motor installation

 
 4.  After the installation have been done, then it continued with the installation of machine body by using prospect. It is to put the PIC circuit, motor, blade motor and 360 degree wheel.



Problem Encountered:

There is no problem appear during this gearbox motor installation. I have to follow the instruction from manufacturer and depending of the types of motor ratio. This task was run smoothly.

 
Project Outcome:

I have learned about how to install the gearbox motor from Tamiya manufacturer and it is need more patient during this process. My research project is on schedule and I should encounter no problems finishing it.  

WEEK 4

Date:  24  - 28 February 2014

Subject : Drilling a hole on each of the components feet and the process of constructing the components on the board.

Introduction: The purpose of this task is to make a hole by using hand drill to put the components to the PCB board.

Objectives: 

1. To put each of components based on the PCB circuit.
2. To make a hole for each of components.

Project Description:

1.  After after etching process have been done, it can started with drill a hole to put the components to  the board. Mini drill have been used for this task. It already have a point on the board and I just need to follow the circuit illustration  to do a hole process.

Figure 1: A hole process on the board

2.  There have a lot of component point that need to drill. from figure 2, it is a process of drill a relay part. then it continued to the other component such as resistor, capacitor, IC and else. 

Figure 2: A hole process at a relay part

3.  After the hole process have been done, then it's time to put all component based on circuit diagram in figure 3.

Figure 3: The component location for PIC circuit

4.  From figure 4, it is the completely PIC circuit for this project. All components need in this circuit have been making by follow to the software.

Figure 4: The completely component making

5.  Then, the soldering process to the all components on the board. Soldering is a process in which two or more metal items are joined together by melting and flowing a filter metal (soldering) into the joint, the filler metal having a lower melting point than the adjoining metal.

Figure 5: The soldering process had been started

Figure 6: The completely soldering process

Problem Encountered:
 
There is no problem appear from this task. All process have been run smoothly without any problems obtained. Some components need to solder in a short time to avoid any damaged to the component  that can make this circuit will not function.

 
Project Outcome:

Many input have been learned from this process. It is need to do with patient to avoid any problems appear for the next task. My research project is on schedule and I should encounter no problems finishing it.  

WEEK 3

Date:  17  - 21 February 2014

Subject : Etching Process

Introduction: Etching is the process of using strong acid  to cut into the unprotected parts of a metal surface to create a design in the metal .

Objectives: 

1. To create a circuit as in software into the PCB board
2. To attached all components used in the board.

Project Description:

1. First, prepared the material used for etching process which are:

• PCB board
• Acid (Ferric Chloride Anhydrous)
• Former
• Heat water

 Figure 1: Some material used for Etching process

2. Second, put the acid  along with the hot water into the container. The acid will melt and change to gold color.

3. Then put the board into the container and I need to shake it slowly. This process will take around 30 minutes to get the exactly circuit.

Figure 2: The board need to be shake with the acid and hot water

4.  From figure 3, the conductor that is not in used will disappear because of the acid reaction. So, the circuit will be obtained after this process.  

Figure 3: The conductor that is not in used slowly disappear from the board

5.  After a few minutes the board will change into exactly circuit that I need. This circuit will need to troubleshoot first if there have some line that is short each other. So, it is need to do a continuity test for this circuit by using multimeter.

Figure 4: The circuit after etching process

Subject : Troubleshoot/Testing Process

Objectives: 

1. To check either the line obtained is not connected with the other route.
2. To avoid any short circuit happened that will make the circuit not functional.

Project Description: 

1.  The continuity testing is most important thing after doing the etching process. It is to check either the line is not connected with other route.

Figure 1: The circuit need to clean using sand paper

 2.  Figure 1 shows the sand paper is using to clean up the circuit from any conductor that is not important.

 Figure 2: The process of continuity testing

3.  By using buzzer, it is need to checked on each route for the continuity test. Sometimes the line is unconnected or missing with the other route or component pin because of the line from permanent marker is not made with properly before etching process.

Problem Encountered:
 
There is no problem interface from the testing process. Each line in the route is well connected and there is no line missing from the circuit. The circuit from etching process is the same with the design in Proteus software.

Project Outcome:

I have learned about how to obtained the circuit from etching process. I'm also can understand the circuit function and the way of each components used in this PIC circuit. My research project is on schedule and I should encounter no problems finishing it.  

WEEK 2

Date:  10  - 14 February 2014

Subject : Printed the PCB layout

Introduction: The purpose of this task is to convert the PCB layout from Proteus software and printed it into transparent paper.

Objectives: 

1. To convert the PCB layout
2. To printed the layout into transparent for etching process

Project Description:

1.  First, it must to convert the circuit into PCB layout by using auto route from the toolbar. it can make the route and compile all the components into suitable places. From figure 1 it is the successful circuit that has been obtained from Proteus software.

Figure 1: The PCB layout

2.  Second is the printed process into transparent paper. This circuit is already mirror so that components will put exactly same as in the figure 1. If the circuit is printed wrongly so the circuit will be not function. 

Figure 2: The printed PCB layout

3.  Then the printed circuit will be put on the board. it is for make the route on the board by using heat from the iron as in figure 3.

Figure 3: Iron is used for make the circuit stick on the board

Figure 4: The circuit that has been printed on the board.

4.  Based on figure 4, the circuit is successful stick on the PCB board but the line to each component need to be checked to avoid any short circuit or voltage error to the components. So, the circuit will be not functional. The line need to be done by using permanent marker pen. Figure 5 shows the line that not fully attached on the board before the circuit is fully successful as in figure 4.

Figure 5: The line is not properly stick on the board

Problem Encountered:
 
There is no problem appear from this work but just a detail work that must be do with patient. This work will make sure the next task will run smoothly. This task need to do with careful because it will determination whether it is successful or not.

Project Outcome:

I have learned about how to convert the circuit into PCB layout and the circuit that has been obtained from the heat. My research project is on schedule and I should encounter no problems finishing it.