Design and hardware development of power window control mechanism using microcontroller

Roushan kumar Assistant Professor, Department of Electronics,

Instrumentation and Control Enginnering, University of Petroleum and Energy Studies, Dehradun, India

E-mail : rkumar@ddn.upes.ac.in

Abstract -- The research paper emphasizes on the design and real time implementation of microcontroller based power window control used as a control system for moving a power window panel. The purpose of power window control system is to raise and lower door glass with the help of a switch and its operation is controlled by the use of following sensors LPG sensor, LOR sensor and position sensor to replace the use of hand-turned crank handle. Power window system consists of driver motor, power electronic and control system. The control unit senses both hard and soft obstructions and deactivates a motor that moves the glass when any obstruction is detected. The controller also senses obstructions on start-up of the motor and regulates the speed of the window panel by pulse width modulating motor signals. In other way the controller senses obstructions by maintaining data which is related to motor operation in three different memory buffers that are regularly updated upon receipt of pulses that are related to motor speed. The whole system can be designed as an intelligent control system by applying number of conditions which results to the movement of the power window. It increases the safety of the automobile as well as increases human comfort inside the vehicle. Such applications are fire safety in the vehicle, over temperature detection, sensing of LPG leakage. Hardware implementation includes some basic input switches, sensors connected to the microcontroller and the LEOs and LCO are used to show the status of output. Input sensors used for this research are LPG sensor, LOR sensor and position sensor, output is the functioning of the motor. The implementation work is carried out using A VR ATMEGA 16 microcontroller.

Keywords - Power Window, A TMEGA 1 6, Electromechanical relay, D. C motor

I . INTRODUCTION

Power window or an electric window system is a part of an automotive element. It is located at the door of vehicle. The purpose of this system is to raise and lower door glass by applying a switch in order to replace the use of hand-turned crank handle i .e . reducing the human effort. Power window system includes power window motor, electronic circuits, control system, number of inputs and outputs .

Many modern cars have a feature of delay, which allows the function of the windows and some other accessories to be operational for ten minutes after the engine is stopped. Another concept is the express-down window, which allows the window to be completely lower with one tap on the switch, as stopped by holding the switch downward until the window reaches the level . Many luxury vehicles in the ancient times

97S-1 -4799-1 607-S/1 3/$31 .00©201 3 IEEE 361

Adesh kumar Assistant Professor, Department of Electronics,

Instrumentation and Control Engineering, University of Petroleum and Energy Studies, Dehradun ,India

E-mail : adeshmanav@gmail. com

during the 1 990s introduced this concept includes the express­up on the driver' s window, and now, some manufacturers have added this feature on all window switches for human convenience. This is done by activating the switch or button until a "click" response is felt.

Power window system is of two types. They are classified as cable type power window system and scissors type power window system. The basic functions for both of them are for raising and lowering the automobile windows using a dc motor controlled by a control unit. The cable type has four parts consisting of electric motor, railing, cable, and switch. The working uses the cable to raise and lower the glass . The window glass is mounted at the carrier plate and the cable is located on the railing surface. Motor is used to rotate the cable so as to move the window up and down using a gear which is attached to the motor and the cable.

The lifting mechanism on most cars uses a linkage to lift the window glass upper or lower while keeping it in level . A small electric dc motor is connected to a worm gear and number of other spur gears to create a large gear reduction, and providing it enough torque to lift the window. The linkage consists of long arm, which is attached to a bar which holds the base of the window. The end of the arm can move in the space as the window rises. On the other end of the bar there is a large plate that has gear teeth cut into it, from which the motor turns a gear that uses these teeth. This is the common linkage used on cars with manual windows, but the difference is that, the crank handle turns, instead of a motor turning the gear.

The organization of paper is as follows : Section 1 presents introduction, section 2 block diagram, section 3 controller design, section 4 experimental setup, section 5 result and discussion. Conclusion & Future work is represented in section 6 .

IT. BLOCK DIAGRAM

The functional block diagram of power window control mechanism is shown in figure 1 . The Microcontroller development board can be used to develop the power window control mechanism. It consists of two switches, when one switch is pressed, the motor will move in forward direction, and window will move upwards. Similarly, when the switch is pressed, the motor will move in reverse direction, and window will move downwards. Relays are used to change the direction from clockwise to anticlockwise direction and vice versa.

2 w

LPG Sensa r

ay s\\itch

lDR

ADC

Micro .. DC Controller P"VM Motor Mechanical

Control Arrangement ......

� Power Supply

Power Supply

Fig. I . Power window control mechanism

Fig. 2. Power Window Circuit Diagram

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In either of the case, two sensors on top and bottom of the window panel are used. The upper and the lower limit of the window is detected by the sensor and the motor stops until the next command is given. There are two sensors, one is LPG sensor and another sensor is LDR. For LPG sensor, a specific value is defined above which it is assumed that there is gas leakage in the automobile and window will move downwards until the lower limit is reached. For LDR sensor, as the sun rays fall on it, the tinted glass will move upward until the upper limit is reached. A flow chart of software development procedure and implementation is illustrated in figure 3 given below.

Press Switch 1 : 1 and Switch 2 = 0

Motor rotates in c l ockwise d i rection and w i ndow w i l l

m ove upward 14------,

M otor stop

Press Switch 1 = 0 and Switch 2 = 1

Motor rotates in anticlockwise d i rect ion and window will move downward

N

y

y

Stop

Fig. 3. Flow chart of functional module

N

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A power window control system used in automobiles to open and close the windows by raising or lower the window. The windows are moved with the help of motors that are controlled with the help of commands generated by the controller and the passengers press switches. These switches may be located anywhere inside vehicle and connected to the window via communication channel. For the effective design of power window control system, it can be divided into four subsystems

• The embedded system • Hardware for signal conditioning • The electrical actuator and circuit • The lift mechanism

With respect to the dc motor and lift mechanism, the embedded controller subsystem is a compound configuration of dc motor and lifting mechanism, which are synchronized. It includes a hardware part and software part that are separated but depends on each other. The power window control system is part of a larger bus/channel connected to the automobile ' s electronic system that can also have the function, e .g . the opening and closing of a sun roof and moving the headlights up and down. So, it is a subsystem which interacts with the window control switches. Again these are subsystems that can be divided into the hardware switches, signal conditioning and circuits.

TTT. CONTROLLER DESIGN

Many challenges exist for designing a vehicle controller. For one thing, the vehicle consists of many large subsystems e .g . engine, motor, transmission, battery, brakes, etc. In addition to being nonlinear and often time varying, each subsystem has its own complexity. The entire power window controller design work is divided into two parts one IS software development and second is hardware design.

Software Development The programming environment consists of a A VR

Studio, version 4, Integrated Development Environment (IDE), which is used to develop the code, debugging software, and a hardware interface for transferring the program on to the processor through USB background debugging module called winA VR to the A TMEGA 1 6 microcontroller. The entire experimental equipment is simulated on the Proteus simulator. Proteus simulator is a simulation toll through which it is possible to simulate all inputs (LPG sensor, LDR sensor, and toggle switch), ATMEGA microcontroller, circuits for motor control and DC Motor. In the simulation, we have used Proteus software in which certain block are A TMEGA 1 6 microcontroller, LEDs and switch connection with ATMEGA 16 , LCD connection with A TMEGA 16 , sensor interfacing with A TMEGA 1 6 and DC motor interfacing with A TMEGA 16 . The overall circuit diagram is listed in figure 2. The detailed software development flow chart is illustrated in figure 3 . The major factors to be considered in selecting a processor are Suitability to Automotive Environment, Support for the sensor interfacing and Programming Environment.

Apart from this the processor is able to operate in the harsh automotive environment like vibrations, humidity, g forces, and temperature extremes.

With the help of simulation results it is observed that the better performance on a detailed vehicle model is achieved.

Hardware Design Power window circuit is classified into five mam

parts • OFF board Power Supply • ON board power supply • Atmega 1 6 Board • Motor Circuitry Board • Sensors interfacing

Off board power supply consists of center-tap step down transformer whose input is 220V & lA and output is 12V- OV-12V & l A, electromechanical Switch for switching ON-OFF the control system, LED for indication of physical system, Resistor of 1 K, bridge rectifier circuit consists of four 1 N4007 diodes, LM78 12 and LM780S voltage regulator IC are used to provide constant 12V for off voltage power supply and SV for on voltage dc power supply, a Capacitor of 1 OOOllf & SOY.

Atmega 16 Board consists of ON board power supply whose output is SV & 600 mA, which is taken from circuit and voltage regulator IC LM780S, A Tmega 1 6 Microcontroller IC, one 16 x 2 LCD for displaying upward and downward movement of power window, LED indicates power ON/OFF status, resistor of 330 K and push buttons for electromechanical switches.

Motor circuitry board consists of Darlington pair whose input is at the base from the microcontroller and output is connected to the relay. It is used to control the large current that is S mA from ATMEGA 1 6, is used to control 2-2. SA current. A freewheeling diode is also used to kill the back electromagnetic force generated from inductive loads like motor and relay. Relay of 12V, 6A with 2N30SS transistor is used for switching the direction of the motor. Sensor consist of infrared (IR) LED which is of purple colour which reflects the light on white surface and photo detector which is black in color detects the light from white surface. The voltage developed by the photo detector is digitized with the help of comparator. Comparator is basically an op-amp LM3SS . The corresponding hardware circuit is shown in figure 2 which is simulated in Proteus.

IV. EXPERIMENTAL SET UP The experimental set up of power window control is shown

in the figure 4, which comprises two LDR sensors used to sense the upward and downward window position and one LPG sensor, used for safety purpose protecting from fire. Two switches are used for upward and downward movement of window. A TMEGA 1 6 is used as an intelligent controller for controlling and switching operation of power window DC motor. The experiment is carried out for different test cases to

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analyze the upward and downward time of power window. The specifications supporting the experimental set up is listed in table l .

LDR SENSOR 1

POWE R WINDOW

LDR SENSOR 2

WINDOW FRAM E

----+----7 INTELLEGENT CONTROLLER

LPG SENSO R

T W O WAY SWITCH

Fig.4 Experimental Set up of power window control

TABLE 1 Hardware Spectitications

Parameters Value

Weight of Window S Kgs Motor Voltage Rating 12 V Max. Rated Torque S Kg-m

No Load Current 2 . S A No Load Speed (SO - 1 00 ) rpm Rated Current S A

V. RESUL T & DISCUSSION

The software development of the prototype is done successfully with the help of win A VR software and tested on Proteus for different test cases. Real time development is done with the help of the hardware modules discussed in the discussion part. It is a simple, economic and cost effective implementation of hardware device which is used by general logics to control the power window. This system can be used in any automobile power window control to protect the person from glass during accidents . In the research work it has been used A TMEGA 1 6 microcontroller for controlling the power window of an automobile. An intelligent control system is designed to increase the safety and luxury in the automobile. It is an automated system and reduced the human effort on their interface with the window. The presented experimental results stress the relevance of the new and simple approach to control power window of a conventional vehicle. The method is very general and can be applied to other vehicle like light vehicle, heavy vehicle, commercial vehicle etc.

The experimental results show optimal solution in comparison to the existing work. The time taken by the power window is 2 . 88 seconds, when the motor movement is upward. Similarly, the time taken by the power window is 2 .62 seconds, when the motor movement is downward. The comparison with the existing work [ 1 5] and [ 1 6] is shown in Table 2 and comparison chart is shown in figure 5 .

TABLE 2 Comparison Parameters

Parameters Experimental Ref [ 1 5] Ref [ 1 6] data

Upward 2 . 88 seconds 3 .27 seconds 4 .00 seconds time Downward 2 .62 seconds 3 .20 Seconds 4 .00 seconds time

Comparision of upward and downward time of power window with existinc data

4 3.5

2.5 • Upward TIme

1.5 • Downward TIme

0.5 o ���----�==�---=��--------�

Experimental

data

Ref [1SI Ref 1161

Fig .5 Comparison of estimated time between ref [ 15 ] and ref [ 1 6]

From the results it is clear that there is 1 1 .9 % reduction in upward time in comparison with [ 1 5 ] , and 28 % with [ 1 6 ] . Similarly, there i s 1 8 .2 % reduction in downward time of power window in comparison with [ 1 5] and 34 .5% with [ 1 6] .

VI. CONCLUSION AND FUTURE WORK

With the design and development of the prototype, the safety of the automobile system can be increased to larger extent. As the number of CNG/LPG Vehicles are increasing day by day due to its efficiency and cost effectiveness, LPG Sensors can be implemented in the automobiles which are using LPG as basic fuel to increase the safety ofthe system. In future the technology can be proposed for higher microcontrollers and extended to provide accidental information in control room with help of navigational system and global positioning system. The research work is compared with the existing work done for the hardware implementation of power window control and it is estimated an optimal solution in terms of optimal upward and downward time. The research work can be extended to include fault tolerance and electromagnetic interference. The abbreviation used in the document is listed in table 3 .

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TABLE 3 List of abbreviations

Abbreviation Description ADC Analog to Digital Conversion CNG Compressed natural Gas LCD Liquid Crystal Display LDR Light Dependent Resistor LED Light Emitting Diode LPG Liquid Petroleum Gas

VII. ACKNOWLEDGEMENTS

We are grateful to the support from the Electrical, Electronics and Instrumentation Engineering department of University of Petroleum and Energy studies, Dehradun, India.

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