0

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

A STUDY AND DEVELOPMENT OF FOUR QUADRANT

H-BRIDGE DC MOTOR CONTROLLER USING PIC18F4550

This report submitted in accordance with requirement of the

Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor‟s

Degree in Electronics Engineering Technology (Industrial Electronics)(Hons.)

by

IDA FAIRUZ BINTI WAHID

B071210031

900116045416

FACULTY OF ENGINEERING TECHNOLOGY

2015

i

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: A Study and Development of Four Quadrant H-bridge DC Motor Controller

using PIC18F4550

SESI PENGAJIAN: 2014/15 Semester 2

Saya IDA FAIRUZ BINTI WAHID

mengakumembenarkanLaporan PSM inidisimpan di PerpustakaanUniversitiTeknikal

Malaysia Melaka (UTeM) dengansyarat-syaratkegunaansepertiberikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk

tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran

antara institusi pengajian tinggi.

4. **Silatandakan ( )

(Mengandungimaklumat yang

berdarjahkeselamatanataukepentingan Malaysia sebagaimana

yang termaktubdalam AKTA RAHSIA RASMI 1972)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungimaklumat TERHAD yang

telahditentukanolehorganisasi/badan di

manapenyelidikandijalankan)

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat dari pada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai

SULIT atau TERHAD.

(TANDATANGAN PENULIS) AlamatTetap: 6722 KM 12

BUKIT KECIL PERNU

75460 MELAKA

Tarikh: ________________________

Disahkanoleh: (TANDATANGAN PENYELIA)

Cop Rasmi:

ii

DECLARATION

I hereby, declared this report entitled A Study and Development of Four

Quadrant H-Bridge DC Motor Controller using PIC18F4550 is the results of

my own research except as cited in references.

Signature : ………………………............

Author‟s Name : IDA FAIRUZ BINTI WAHID

Date :

iii

APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Engineering

Technology Department of Electronics & Computer Engineering

Technology(Hons.). The member of the supervisory is as follow:

………………………………………………

EN. A SHAMSUL RAHIMI BIN A SUBKI

v

ABSTRACT

Recently, motor applications not only use the maximum speed. It maybe uses

only 5% of its speed. So, the speed of the motor must be control. For some applications,

motor is using not only one direction but with alternate direction to control a machine. In

industrial field, DC motor acting an important part in industrial. Besides, in modern era

the manual controller is also not practical which can waste cost and time. According to

this situation it is important to make a controller to control the speed of DC motor which

user can monitor their system at certain place rather than going to the plant. Therefore,

the aim of this project is to control direction either forward or backward of DC motor by

using microcontroller and to study speed control of DC motor using PWM technique. It

is operated by four quadrant H-Bridge DC motor controller using PIC18F4550.Four

Quadrant Circuit is used in this circuit. It is create by using simulation software known

as Proteus software. The simulation is also done for testing the four quadrant and also

the control circuit. Four MOSFETS are used in the four quadrant circuit. Two of them

are TIP 41C and TIP 42C. The four quadrant operation of the dc motor is best suited for

industries where motors are used and as per requirement as they can rotate in clockwise,

counter-clockwise and also apply brakes immediately in both the directions. The motor

is controlled by using PWM which is pulse with modulation. It is observed that the

voltage increases as the PWM increases. The maximum of the PWM is 255 whereas the

maximum voltage is 5.101V. The LCD is also used in this project to show the

maximum and minimum of the PWM. Overall, with this project, it can control not just

the PWM, but the speed of the motor.

vi

ABSTRAK

Pada masa sekarang, aplikasi motor tidak hanya digunakan pada kelajuan

maksimum. Kemungkinan hanya menggunakan 5% sahaja kelajuannya. Maka, kelajuan

boleh dikawal. Apa sesetengah aplikasi, motor tidak digunakan dalam satu arah untuk

mengawal mesin. Dalam bidang industry, DC motor memainkan peranan yang amat

penting. Pada era ini, kawalan manual juga tidak praktikal di mana dia amat membuang

masa dan juga kos. Daripada situasi ini, kawalan had kelajuan amat berguna di mana

pengguna boleh melihat keadaan yang berlaku. Dengan ini, objektif di dalam projek ini

adalah untuk mengawal pergerakan motor dalam keadaan arah jam, arah lawan jam dan

brek untuk berhenti pergerakan motor menggunakan kawalan mikro dalam masa yang

sama kawalan kelajuan dapat dikaji dengan menggunakan teknik Pulse width

modulation (PWM). Ia menggunakan 4 kuadran jambatan H DC motor dengan

menggunakan PIC18F4550. Litar jambatan H atau H-Bridge digunakan dalam projek

ini. Simulasi juga digunakan dengan menggunakan Proteus dan barulah litar tersebut di

lakukan secara praktikal. Empat MOSFET digunakan di dalam litar H-Bridge iaitu

TIP41C dan TIP42C. Litar H-Bridge adalah pilihan yang bagus untuk pengoperasian

putaran arah jam, lawan arah jam dan juga brek yang berlaku secara segera. Motor

dikawal dengan menggunakan PWM di mana ia mengawal kelajuan. Pemerhatian

terhadap kenaikan nilai voltan dikaji iaitu 5.101V pada voltan yang maksima pada nilai

masukan 8V. Paparan LCD 16x2 juga digunakan untuk memaparkan maklumat. Pada

keseluruhannya, projek ini bukan hanya untuk mengawal PWM sahaja malah ia

mengawal kelajuan motor.

vii

DEDICATIONS

I would like to dedicate this project to my beloved supervisor, En. A Shamsul

Rahimi bin A Subki who give extra knowledge to assists me develop this project. I also

want to thanks to my family members, lecturers and friends that give me extra spirit to

continue develop this project.

viii

ACKNOWLEDGMENTS

Alhamdulillah, praise be to Allah for His blessings and giving me the strength

along the challenging journey of completing the project as well as this thesis writing, for

without it, we would not have been able to come this far.

Primarily, we would like to take this opportunity to express my deepest gratitude

towards my project supervisor, En. A Shamsul Rahimi bin A Subki who has Persistently

and determinedly assisted me during the project. It would have been very arduous to

complete this project without the passionate supports and guidance encouragement and

advices given by him.

We outmost thanks also go to my family who has given me support throughout

my academic years. Without them, we might not be able to become who we are today.

we grateful to have love affection and care from all of my family members as well. My

fellow friends should also be recognized for their continuous support and

encouragement. we sincere appreciation also extends to my entire course mate and

others who have provided assistance at various occasions. Their views and tips are

useful definitely.

Last but not least, thanks to individuals that has contributed either directly or

indirectly to make this thesis project. Without all these people encouragement, support,

and advices this thesis project might not be successfully carried out. Of course, as usual,

all errors and oversights are entirely my own. Thank you once again

ix

TABLE OF CONTENT

Borang Pengesahan i

Declaration ii

Approval iii

Abstract iv

Abstrak v

Dedication vi

Acknowledgements vii

Table of content ix

List of Figures xii

List of Table xiv

CHAPTER 1: INTRODUCTION

1.1 Background 1

1.2 Problem Statement 2

1.3 Objective 2

1.4 Scope of the project 3

1.5 Thesis Outline 4

CHAPTER 2: LITERATURE REVIEW

2.1 Introduction 5

2.2 Types of DC Motor 5 – 8

2.2.1 DC Motor 7

2.2.2 Servo Motor 7

2.2.3 Stepper Motor 8

2.3 Previous Research 9 –19

x

2.3.1 Working and Analysis of the H– bridge Motor

Driver Circuit Designed for Wheeled Mobile Robots 9

2.3.2 Speed Control for DC Motor with Pulse Width

Modulation (PWM) Method using Infrared Remote 11

Control based on Atmega16 Microcontroller

2.3.3 DC motor braking (dc machines braking) 12

2.3.3.1 Dynamic or Rheostatic Braking 13

2.3.3.2 Plugging or counter current braking 14

2.3.3.3 Regenerative braking 15

2.3.4 Programmable Interface Controller (PIC) 17

2.3.5 DC Motor Speed Control 18

2.4 Previous Simulation Software Uses

2.4.1 Proteus VSM 19

2.4.2 Circuit Simulation ProSPICE 20

2.4.3 MPLAB 21

2.4.4 PICkit2 21

CHAPTER 3: METHODOLOGY

3.1 Introduction 22

3.2 Project Overview 23

3.2.1 Flow Chart 24

3.3 Software Overview 26

3.3.1 Proteus V7.7 27

3.3.2 PIC C Compiler 27

3.3.3 PICKit2 V2.6 27

3.4 Hardware Overview

3.4.1 Component Selection 26

3.4.2 Microcontroller PIC18F4550 28

3.4.3 Fabrication Process 28

xi

3.4.4 Developing Process 29

3.5 Software Overview

3.5.1 Proteus V7.7 30

3.5.2 PIC C Compiler 31

3.5.3 PICKit V2.6 31

CHAPTER 4: RESULT AND DISCUSSION

4.1 Introduction 32

4.2 Four Quadrant System 32

4.3 Four Quadrant Operation 33

4.4 Braking System in Four Quadrant DC Motor 35

4.5 Controlling DC Motor with PWM 36

4.5.1 Digital Input 38

4.5.2 Controlling Pulse Width Modulation(PWM) 39

4.5.3 Develop LED‟s and LCD Display Application 40

4.6 Program Source Code 41

4.6.1 Software Implementation 44

CHAPTER 5 : CONCLUSION AND FUTURE WORK

5.1 Introduction 44

5.2 Summary

REFERENCES 46

APPENDIX

xii

LIST OF FIGURE

2.1 DC Motor 6

2.2 Servo Motor 7

2.3 Stepper Motor 8

2.4 H- Bridge Motor Driver Circuit 9

2.5 Speed Control for DC Motor with Pulse Width Modulation 11

(PWM) Method Using Infrared Remote Control Based on

ATmega16 Microcontroller

2.6 Flow of dynamic braking of DC Machines 13

2.6.1 Braking current equation 14

2.6.2 Dynamic torque equation 14

2.6.3 Armature current equation 15

2.6.4 Armature current for regenerative braking equation 16

2.6.5 regenerative braking torque equation 16

2.6.6 Speed torque equation 16

2.7 Flow of counter current braking of DC Machines 15

2.8 Speed vs time curves for various braking methods 16

3.1 The overview of H-Bridge DC motor using microcontroller 23

3.2 Flow chart of overall project 24

3.3 Microcontroller Embed with PIC18F4550 28

3.4 LED‟s PCB layout 29

3.5 H-Bridge PCB layout 29

3.6 Push button PCB layout 29

3.7 Etching process 29

3.8 Simulation design four quadrant using H-Bridge circuit 30

3.9 PIC C Compiler Software 31

3.10 PICkit2 V2.60 Software 31

4.1 Four quadrant circuit using PIC18F4550 29

4.2 The etching H-bridge circuit 34

xiii

4.3 Four quadrants of operation 35

4.4 Operating Modes 35

4.5 Formula PWM duty cycle 37

4.6 30% duty cycle reading 38

4.7 60% duty cycle reading 38

4.8 Push button as digital inpit 39

4.9 Variable resistor 39

4.10 LCD display 40

4.11 LED indicator 41

4.12 Define pin PORT 44

4.13 Define analog input 44

4.14 Define motoring modes 45

4.15 Define LED‟s

xiv

LIST OF TABLE

2.1 Characteristics of BD 139 and BD 140 10

3.1 List of Component 26

4.1 Basic Table for 4 Quadrant H-Bridge using PIC18F4550 33

4.2 The data collection by practically 37

4.3 The condition of LED‟s when PWM value 0 to 255 41

4.4 The source code 42

1

CHAPTER 1

INTRODUCTION

1.1 BACKGROUND

The main goal for this project is to build a motor controller that can control a DC

motor with a digital input. For the purpose of this project, a microcontroller is use to turn

the motor in four quadrant which are forward, reverse, forward breaking and reverse

breaking. There should be one digital input for forward and one digital input for

backward. Additionally the board should have two terminal blocks, one for the motor's

power and one for connecting the H-bridge to the motor.

As an application of H-Bridge motor controller (DC motors) can be used as wheel

drive machines and by using a simple microcontrollerPIC18F4550 the rotation of motors

or motion of the robots can be controlled easily. The motion of the motor is based on the

concept of differential mechanism. The prerequisites are DIY PCB (Etching), DC Motor

Control and H-Bridge circuit

2

1.2 PROBLEM STATEMENT

In real world, motor applications not only use the maximum speed. It maybe

uses only 5% of its speed. So, the speed of the motor must be control. For some

applications, motor is using not only one direction but with alternate direction to control

a machine. In industrial field, DC motor acting an important part in industrial. There are

some types of applications need the load on the DC motor varies a speed range such as

high precision digital tools, rolling mill, and double-hulled tanker.

Besides, in modern era the manual controller is also not practical which can

waste cost and time. According to this situation it is important to make a controller to

control the speed of DC motor which user can monitor their system at certain place

rather than going to the plant. Furthermore this system is more precise and reliable

which can reduced the man power. The hardware may be need a higher cost with

maintenance but the low cost electronic devices can be design for this system but some

machine or robot cannot get in touch according to safety and the location of those things.

The system will create the program source code and conduct by designing circuit which

contains H-bridge circuit, control circuit and DC motor

1.3 OBJECTIVES

The project objective contains in two part which are primary objective and secondary

objective. Primary objectives are about the direction of the motor rotation and PWM

technique. While secondary objective are about the source code and the four quadrant

system of DC motor.

3

1. To control direction either forward or backward of DC motor by using

microcontroller.

2. To study speed control of DC motor using PWM technique.

3. To develop a source code using assembly language of the microcontroller

1.4 PROJECT SCOPE

Project scope have two categories must be archive. It is start from software

implementation until hardware installation. The project is implemented based on the

scope. Among them :

1) Design a circuit for controlling motor of DC motor.

i. The H-Bridge.

ii. Motor Control Hardware with a PIC.

iii. Integration to Control a DC Motor.

2) Develop programming for the microcontroller.

4

1.5 THESIS OUTLINE

Chapter 1 :

This chapter introduces brief idea of the project. It focused on the overview of the

project, detailing the objectives, the problem statement, scope and outcome of the

project.

Chapter 2 :

Projects background is discussed in this chapter. The method concept, theory, and some

characteristic of component of hardware that are used in this project is discussed in this

chapter. This chapter also defines terms used in this project and discussed the concept of

the research and how it is related with the theory.

Chapter 3 :

Describes the methodology used in this project. The schedule or steps that need to be

completed and the detailed reports of studies that were done to achieve the aim of the

project are presented.

Chapter 4 :

This chapter presents the result and discussion. All the simulations, data collection and

analysis obtained will be discussed in detail. The results will be compared with the

objectives outlined in order to arrive to some hypothesis and conclusion.

Chapter 5:

The conclusion and future work that can be undertaken. Some recommendations and

suggestion on how to improve the performance of the system based on the desired

results will be given.

5

CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

Literature review is used as one of the method for the purpose of learning and to gain

more knowledge in terms of project, designing the circuit and also to understand in

details on the problem of designing the DC motor circuit.

2.2 TYPES OF DC MOTOR

2.2.1 DC motor

DC motors are one of the simplest types of motors to be controlling. A few DC motors

that I will use to test the circuit, anything that doesn't require more than 10A to move

will do.

6

The first consideration is the motor‟s nominal voltage. DC motor as in figure 2.1

is controllers tend to offer a voltage range. For example, if the motor operates at 3V

nominal, it should not select a motor controller that can only control a motor between

6V and 9V.

Figure 2.1 DC Motor

Once found a range of controllers that can power the motor with the appropriate

voltage, the next consideration is the continuous current the controller will need to

supply. Find a motor controller that will provide current equal to or above the motor‟s

continuous current consumption under load. Should be choose a 5A motor controller for

a 3A motor, the motors will only take as much current as they require. On the other

hand, a 5A motors is likely to burn a 3A motor controller. Many motor manufacturers

provide a DC motor‟s stall current, which does not give a clear idea of the motor

controller will need. If cannot find the motor‟s continuous operating current, a simple

rule of thumb is to estimate the motor‟s continuous current at about 20% to 25% of the

stall current. All DC motor controllers provide a maximum current rating – be certain

this rating is about double that of the motor‟s continuous operating current. Note that

when a motor needs to produce more torque (for example going up an incline), it

requires more current. Choosing a motor controller with built-in over current and

thermal protection is a very good choice.

7

The Control method is another important consideration. Control methods

include analogue voltage, I2C, PWM, R/C, UART (a.k.a. serial). If using a

microcontroller, check to see which pin types have available and which motors are

viable to choose. If the microcontroller has serial communication pins, choose a serial

motor controller; for PWM, will likely need one PWM channel per motor.

2.2.2 Servo Motor Control

Since standard hobbyist servo motors are meant to use specific voltages (for peak

efficiency), most operate at 4.8V to 6V, and their current consumption is similar, the

steps for the selection are somewhat simplified. However, it may find a servo motor as

shown in Figure 2.2 that operates at 12V; it is important to do additional research about

a servo motor controller if the servo motor is not considered “standard”.

Figure 2.2 Servo Motor

Also, most hobby servo motors use the standard R/C servo input (three wires

which are ground, voltage and signal). Choose the control method. Some servo motor

controllers allow to control the servo‟s position manually using a dial/switch/buttons,

while others communicate using UART (serial) commands or other means. Determine

the number of servos to be controlled . Servo controllers can control many servos

(usually 8, 16, 32, 64 and up). As with DC motor controllers, the control method is an

important consideration.

8

2.2.3 Stepper Motor Control

A stepper motor as shown in Figure 2.3 is controller type accordingly, though a

growing number are able to control both types. The number of leads is usually a

dead give-away of the motor type: if the motor has 4 leads, then it is bipolar; should it

have 6 or more leads, then it is unipolar.

Figure 2.3 Stepper Motor

Choose the motor controller voltage range to match that motor‟s nominal

voltage . Find out how much current per coil the motor requires, and find out how much

current (per coil) the stepper motor controller can provide . Using Ohms Law (V=IR),

then calculate the current (I). As with DC motor controllers, the control method is an

important consideration.

9

2.3 PREVIOUS RESEARCH

Before beginning the process of designing a h-bridge circuit, some of the existing circuit

should be learn.

2.3.1 Working and Analysis of the H– bridge Motor Driver Circuit Designed for

Wheeled Mobile Robots from Vibhor Gupta, University Institute of Engineering

and Technology, Panjab University, Chandigarh (2000).

Figure 2.4 H- Bridge Motor Driver Circuit

Simulation and construction of circuits, National instruments Multisim

“www.ni.com/help”[8]

10

The DC geared motor will work in two directions (Clockwise or anticlockwise)

depending upon the direction of flow of current from it. The Inputs A and B will be fed

from the microcontroller PIC 16F 877A [2] refer Figure 2.4. Transistors Q1 and Q4 and

transistors Q2 and Q3 are given the same input. When A is HIGH, while B is LOW,

transistors Q2 and Q3 triggers making the movement of the motors in one direction.

Similarly when A is LOW, while B is HIGH, transistors Q1 and Q4 triggers making the

direction of the motor opposite.

The transistors used are BD 139(NPN) and BD 140(PNP) as shown in Table 2.2.

These are power transistors which are able to withstand the high starting current of the

motors due to starting torque from the gears, unlike simple BJT‟s.

TABLE 2.1 Characteristics of BD 139 and BD 140 [3]

Symbol Parameter Max. Unit

VCBO Collector-base voltage 100 V

VCBO Collector-emitter voltage 80 V

IC Collector current (DC) 1.5 A

Ptot Total power dissipation 8 W

hFE DC current gain

IC = 150mA ; VCE = 2V 250 V

A drive system for the wheeled mobile robots should be efficient enough to

provide good movement. The circuits explained will help to make a drive system

efficient and is able to work at heavy load conditions with proper switching.