"Solar Module Cleaning Robot," is an innovative and technologically advanced system designed to automate the cleaning process of solar panels. The core of your system lies in the ESP32-IE dual-core microcontroller, which serves as the brain of the robot. This microcontroller not only interfaces with the cleaning mechanisms but also incorporates user-friendly controls through a 4x4 keypad and a 16x2 LCD display and remote control via a WiFi-based mobile interface. The inclusion of the DS3232 IC for real-time clock functionality ensures synchronization between the set time and the actual time, enabling scheduled cleaning routines.

To navigate through the solar module table, you've implemented two inductive proximity sensors - one at the end and the other at the home position. These sensors, operating on NPN type, effectively trigger the cleaning process when the scheduled time aligns with the real-time clock. The use of PWM-based motor controls adds precision to the robot's movements, ensuring accurate positioning and reliable cleaning operations.

The EEPROM in the ESP32 is utilized to store hour and minute information, allowing for comparison with the real-time clock to initiate the cleaning sequence. The integration of a 219 current sensor serves as a safety feature by monitoring load current continuously. Any abnormal inrush current triggers a halt in operations, ensuring the system's robustness and preventing potential damage.

Communication with the master control room (MCR) is established through a WiFi connection, facilitated by a 6dbi antenna. The use of HTTP protocol for data exchange, involving both GET and POST methods, ensures effective communication between the robot and the control center. This connectivity enables remote monitoring and control, enhancing the overall efficiency of the cleaning operations.

Your project exhibits versatility with different operational modes, including Automatic, Manual, and Emergency modes. This flexibility enhances the adaptability of the robot to varying circumstances, providing a comprehensive solution for solar panel maintenance. Overall, your solar panel cleaning robot project showcases a well-integrated system with a focus on precision, safety, and efficient communication for optimal performance.

While the existing mechanical assembly is utilized, the focus of my design has been on the development of the system controller and power management PCB, ensuring a robust and efficient core for the Solar Panel Module Cleaning Robot.

Rs485 Serial communication protocol

 RS-485

Serial communication protocol is capable of transmitting digital serial data up to maximum distance of 4000 m or 4 km. But normally after 1200 m the signal starts drooping off and transmitted signal starts losing its strength due to which their is slight chance of data loss. To achieve 4 km successful data transmission the carrying medium should be smooth and the length of A and B lines should be equal-distance in length. External EMF(Electro Motive Force) also effects the lines carrying the data.

• DI (Data In) Data on DI pin is transmitted on A & B lines when the module is in transmit mode. To set module in transmit mode make DE=1 and RE=1. DI pin is connected to Tx pin of Host Microcontroller UART.
• RE (Receive Enable) RE pin is Used to configure the module in Receive Mode.
• DE (Data Enable)    DE pin is Used to Configure the module in Transmit Mode
• RO (Receive Out)  Data Received on A & B pin is given to RO pin. RO pin is connected to Rx pin of microcontroller. 
• A & B (Differential Input and Output Pins) Data is transmitted and received on A & B lines.

RS232 Serial Communication Protocol

 RS232 Communication Protocol. The term RS232 stands for "Recommended Standard 232" and it is a type of serial communication used for transmission of data normally in medium distances.

Serial communication – you are shooting a target using machine guns, where bullets reach one by one to the target.

Asynchronous Data Transfer – The mode in which the bits of data are not synchronized by a clock pulse. Clock pulse is a signal used for synchronization of operation in an electronic system.

Voltage Levels: RS232 also used as ground & 5V level. Binary 0 works with voltages up to +5V to +15Vdc. It is called as ‘ON’ or spacing (high voltage level) whereas Binary 1 works with voltages up to -5V to -15Vdc. It is called as ‘OFF’ or marking (low voltage level).

Received signal voltage level: Binary 0 works on the received signal voltages up to +3V to +13 Vdc & Binary 1 works with voltages up to -3V to -13 Vdc.

Line Impedances: The impedance of wires is up to 3 ohms to 7 ohms & the maximum cable length are 15 meters, but new maximum length in terms of capacitance per unit length.

Operation Voltage: The operation voltage will be 250v AC max.

Current Rating: The current rating will be 3 Amps max

main the use of this serial communication is used for the MAX232 ic it is came from dip packages

Generally, a microcontroller works at TTL of about 0 to 5V while a computer operates on the standards of RS232 like -25 to +25V. So interfacing a computer with a microcontroller is not possible without a MAX232 IC. For example; if you want to connect a PIC microcontroller to the serial pin of a laptop, then you must place MAX232IC among them.

• Pin-1(C1+): The positive terminal of a capacitor is connected to this pin
• Pin-2(Vs+): The capacitor’s positive leg is connected to it by grounding the negative leg.
• Pin-3(C1-): The negative pin of the capacitor is connected to this pin and the positive pin is connected to pin1
• Pin-4(C2+): The positive terminal of a capacitor is connected to this pin
• Pin-5(C2-): The negative terminal of a capacitor is connected where the positive terminal is connected to Pin4.
• Pin-6(Vs-): The negative terminal of a capacitor is connected to this pin & 5 volts is provided to the positive terminal of the capacitor.
• Pin-7(T2OUT): It provides the converted TTL signal in the form of RS-232. Here TTL signal can be obtained by T2IN Pin from the microcontroller and this pin is connected to Pin2 of DB-9 port of your computer like Rxd.
• Pin-8(R2IN): This Pin gets the signal of RS-232 like an input & provides the changed signal in the form of TTL on the R2OUT pin. This pin is connected to DB9 Port’s Txd pin, which is Pin3.
• Pin-9(R2OUT): It provides the signal changed within TTL form. The signal is received from Pc at R1In Pin. Connect this pin to your module (TTL) Rxd pin which receives the signal.
• Pin-10(T2IN): This pin gets transmitted signal from microcontroller & gives the changed RS-232 signal over T2OUT pin. Here, the signal can be transmitted from the microcontroller serial port’s txd pin. This pin can be connected to your Txd pin of the module.
• Pin-11(T1IN): This pin works like a T2IN.
• Pin-12(R1OUT): This pin works like an R2OUT.
• Pin-13(R1IN): This pin works like an R2IN.
• Pin-14(T1OUT): This pin works like aT2OUT.
• Pin-15(GND): This pin is a GND pin.
• Pin-16(VCC): This pin is a voltage supply pin where 5V is provided to this pin.

finally successfully simulated rs232 protocol in proteus

TROLLY DESIGN FUSION 360

                                                              Fusion 360

Fusion 360 helps students and educators prepare for the future of design. It's the first 3D CAD, CAM, and CAE tool of its kind, connecting your entire product development process into one cloud-based platform. Download the software today, then turn your ideas into reality

task : design a tri wheel trolley fusion 

 this trolley used for goods  transformation for one place to another place  

7SEGMENT DISPLAY DIGITAL CLOCK WITH OUT RTC

 7 SEG DISPLAY BASED DIGITAL CLOCK USING ARDUINO MINI .

7-segment displays contain 7 (or 8) individually addressable LEDs. The segments are labeled A to G and some displays also have a dot (the 8th LED). Use this image as a reference when setting the individual segments in the code later.

 

TM1637 IC is available in DIP20/SOP20 over here we are providing in SOP20 package. TM1637 IC provides excellent performance and high quality, which is mainly applicable to the display drive of induction cooker, micro-wave oven and small household electrical appliance.

 

 

 

ESD METER

                                                                ESD - METER 

  Static charges can be measured and determined in objects using electrostatic meters by measuring the electric field . Therefore, those charges that are otherwise imperceptible to man when discharged can be registered (< 2.000 V). Electrostatic meters should always be used for ESD protection. 

                                      SIMULATION  OF THE ESD METER CIRCUIT 

 

  IT MEASURES ESD FOOTWEAR RESISTANCE ,  GOOD RESISTANCE =   50>

IF ITSINCREASE, ESD RESISTANCE ABOVE 50 OHM IT CAN'T ABLE TO DISCHARGE CHARGES. SO IT WILL AFFECTING ELECTRONICS COMPONENTS.

IN THIS CASE  WE CHECK FOOTWEAR RESISTANCE BOTH RIGHT LEG AND LEFT LEGS, BOTH LEGS ESD FOOTWEAR HAVE LESS THAN 50 OHM CONDITION PASS.SO DI PAYED PASS  OTHERWISE IT   DISPLAYED FAILED OHM VALE AND DISPLAYED FAILS RIGHT OR LEFT OR BOTH. 

ARDUINO CODE BELOW

 

 #include<LiquidCrystal.h>

LiquidCrystal lcd(2,3,4,5,6,7);   //rs,e,d4,d5,d6,d7

int Vin=5;        //voltage at 5V pin of arduino
float Vout=0;     //voltage at A0 pin of arduino
float R1=3300;//value of known resistance
float R3=3300;
float R2=0; //value of unknown resistance
float R4=0;
int LEFT=0;
int RIGHT=0;
int right=11;
int left=12;
int pass=13;

float buffer=0;            

void setup()
{
  lcd.begin(16,2);
lcd.print("ESD METER");
 delay(500);
lcd.clear();  

}


void loop()
{
  LEFT=analogRead(A0);
  if(LEFT)
  {
    buffer=LEFT*Vin;
    Vout=(buffer)/1024.0;
    buffer=Vout/(Vin-Vout);
    R2=R1*buffer;

    lcd.setCursor(0,1);
    lcd.print("L = ");
    lcd.print(R2);
    
    
  }
 
    RIGHT=analogRead(A1);
  if(RIGHT)
  {
    buffer=RIGHT*Vin;
    Vout=(buffer)/1024.0;
    buffer=Vout/(Vin-Vout);
    R4=R3*buffer;

    lcd.setCursor(0,0);
    lcd.print("R = ");
    lcd.print(R4);
    
    
  }
 
  if((R2>50)&&(R4>50))
 {
 digitalWrite(right,HIGH);
 digitalWrite(left,HIGH);
 digitalWrite(pass,LOW);
 lcd.setCursor(12,0);//right
    lcd.print("FAIL");
   lcd.setCursor(12,1);//left
    lcd.print("FAIL");
   delay(300);
 
 }
else
{
digitalWrite(right,LOW);
 digitalWrite(left,LOW);
 
}

if((R2<50)&&(R4>50))
 {
 digitalWrite(right,LOW);
 digitalWrite(left,HIGH);
 digitalWrite(pass,LOW);
lcd.setCursor(12,0);
    lcd.print("FAIL");//right fail
     lcd.setCursor(12,1);//left pass
     lcd.print("PASS");
      delay(300);
 
 }
 
else
{
digitalWrite(right,LOW);
 digitalWrite(left,LOW);
 
}


if((R2>50)&&(R4<50))
 {
 digitalWrite(right,HIGH);
 digitalWrite(left,LOW);
 digitalWrite(pass,LOW);
 lcd.setCursor(12,0);
    lcd.print("PASS");//right fail
    lcd.setCursor(12,1);
    lcd.print("FAIL");//left pass
     delay(300);
 }
 
else
{
digitalWrite(right,LOW);
 digitalWrite(left,LOW);
 
}


if((R2<50)&&(R4<50))
 {
 digitalWrite(pass,HIGH);
 lcd.setCursor(12,0);
    lcd.print("PASS ");
   lcd.setCursor(12,1);
    lcd.print("PASS ");
    
 }
else
{
digitalWrite(right,LOW);
 digitalWrite(left,LOW);
 digitalWrite(pass,LOW);
}



}
 

ARDUINO SERIAL COMMUNICATE PYTHON

I DONE ARDUINO AND PYTHON SERIAL COMMUNICATION.A SMALL PROTEUS SIMULATION WITH  PYTHON 2.7 ,OUR ULTIMATE AIM OF THE PROJECT ARDUINO SEND A DATA VIA SERIAL PORT THEN PYTHON READ THE SERIAL PORT DATA AND PRINT THE DATA.

 

 PROTEUS :IT IS A ELECTRONIC AUTOMATION SIMULATION ENVIRONMENT IT SUPPORTS ARDUINO AND IT'S SENSORS MODULE ,ITS EASY AND CONVENIENT FOR CIRCUIT MAKING AND WATCHING THE SIMULATE THE CIRCUIT PERFORMANCE .

 

PYTHON  :PYTHON IS A HIGH LEVEL AND GENERAL PURPOSE PROGRAMMING LANGUAGE  ITS OFTEN USED THE SOFTWARE DEVELOPER AND CONTROL MANAGEMENT AND WEB DESIGNING .

 

 

 ABOVE VIDEO FOR THE OUR PROJECT

 OVER ALL THE PROJECT IS NOW WE TRANSMIT THE DATA ARDUINO AND RECEIVE THE DATA PYTHON CODE AND DISPLAY IT 

IN BETWEEN COMMUNICATION ARDUINO AND PYTHON COM PORT BAUD RATE 9600 SET.

PYTHON CODE ARE:

import serial // LIBRARY ALLOWS THE SERIAL COMMUNCATION
i=("scan QR")
print("QR CODE IS",i) // SCAN THE QR VALUES
ser=serial.Serial('COM2',9600,timeout=10) 
data=ser.readline()
print(data)
import datetime
nov=dateline.dateline.nov()
print(nov.strftime("%y/%m/%d  %H:%M;%S"))

 

 ABOVE PROGRAM DEVELOPED THE PYTHON IDE AND IT VERY EFFICIENT PROGRAM .

 

 

#include "LiquidCrystal.h"
LiquidCrystal lcd(12, 11, 5, 4, 3, 2);
double offset = 2.5;
double sensor = 0.066;
double current = 0;
double tension = 0;


const int voltageSensor = A1;

float vOUT = 0.0;
float vIN = 0.0;
float R1 = 30000.0;
float R2 = 7500.0;
int value = 0;


void setup()
{
 Serial.begin(9600);

  lcd.begin(16,2);
  lcd.setCursor(1,0);
lcd.print("bOAT");
delay(1000);

}
void loop()
 {
double value = analogRead(A0);
tension= (value*5.0)/1024;
current= (tension-offset)/sensor;

value = analogRead(voltageSensor);
  vOUT = (value * 5.0) / 1024.0;
  vIN = vOUT / (R2/(R1+R2));
 
  lcd.setCursor(0,0);
  lcd.print("voltage =");
  lcd.print(vIN);
  delay(500);
lcd.setCursor(0,1);
lcd.print("Current=");
lcd.print(current );
delay(500);

/////////////////////////////////////////////////////////////////////////////////////////////////
if(Serial.available());
{


Serial.print("voltage=");
Serial.print(vIN);
Serial.print("  current=");
Serial.println(current);
}

/////////////////////////////////////////////////////////////////////////

 }

 

WHATEVER ITS PRINT SERIAL MONITOR THAT DATA FITCH PYTHON AND DISPLAYING IT.

 

 

FM TRANSMITTER

                                    FM TRANSMITTER

We using two number 2N2222  NPN transistor its transition frequency 300 MHz it enough to transmit FM Wave and processes the Audio signals.

Above show circuit diagram resistor R2,R3 are biasing resistor capacitor C1 act as the filter C2 capacitor works on coupling both circuit.


Transistor works on Pre-amplifier  it amplify the audio signal  2n2222 it gives the best performance high frequency applications.



carrier frequency are generated LC tank circuit it has combination of  22nF & 100nH

calculate the resonant frequency came = (F)=1/2ㄫx√LC.

Transistor Q1 works like the merge the  audio signal and carrier signal.

PCB layout are shown on bellow it is single layer design.

ASSEMBLY LINE BALACEING (my activity)

 

BASIC TIME CALCULATION

SHIFT DURATION                            = 8 HRS 

WORKING HRS                                = 7HRS 
WORKING MINITUS PER DAY     = 420 min
 PRODUCTION TARGET                = 1000 UNITS  

PRODUCTION TARGET PE/ WEEK = 6000 UNITS

WORKING MINITUS PER WEEK = 420X 6          = 2520 min

 

DETAILS ABOUT ASSEMBLY LINE

 SEQUENTIAL DIAGRAM

 

 TASK TIME

 

TOTAL TASK TIME = ∑ (SUM OF ALL THE STATION CYCLE TIME)

TOTAL TASK TIME = ∑ (11.9 + 15.8 + 28.4 + 6.48........+ 120.6+184.6)

 

 TOTAL TASK TIME  = 881.98 SEC

 

 

CYCLE TIME REQUIRED = (PRODUCTION TIME PER DAY) / (UNIT REQUIRED PER DAY)

        = (420)/(100)

        = 4.2 MIN

  

NUMBER OF WORK STATION NEEDED = (TOTAL TASK TIME) / (CYCLE TIME)

= 881.98/42

= 20.9 ≈ 21 STATIONS  

 

LINE EFFICIENCY = (SUM OF TOTAL TASK TIME ) / (NO OF WORK STATIONS  X  60 SEC)  X 100

=(881.98)/(21*60)*100

=70%

BALANCED DELAY EFFIENCY = (100%  -  LINE EFFICIENCY)

 = 100% - 70%    = 30 %

(Not possible to achieve 100 efficiency)

 

LABOUR PRODUCTIVITY = (LABOUR WORKING HOURS     PER WEEK) / (UNIT PRODUCED PER WEEK) X100

=(42*60) / (6000)

 =42%