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Electronic Card Lock System

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1.INTRODUCTION

There is tough competition among manufacturers to provide the

very best of electronic gadgets at the very least cost. No field

has been left untouched. A lot of equipments has been

developed which has improved efficiencies in all fields.

In our day to day life we are using different lock systems for

various securities and other means. Here we introduced our

product Electronic card lock system which can be used as

a lock for important electrical/electronic appliances in our daily life.

Electronic card lock system works with the help of punched cards. When a card is inserted into the system,

depending upon the punched hole on the card, a particular appliance will be switched on. By using our electronic

card lock system we can control only up to seven appliances and each appliance is controlled by a punched card.

High performancefilters

insertion loss up to 100dB Forshielded room/EMP bunkers

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2.BLOCK DIAGRAM

3.BLOCK DIAGRAM DESCRIPTION

Block diagram consist of eight blocks:- 1. Light source 2. Phototransistors 3. Buffer Circuit 4. Enable Detector 5. Relay driver 6. Relays 7. Power supply 8. Output or to appliances

Light source It consists of an incandescent lamp, to provide light to the base of phototransistors.

Phototransistors This section is used to convert the incoming light signal into corresponding electrical signal. This blockconsists of phototransistors and resistors.

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Buffer circuit The output from above block is fed to this block which produce three output states that is, high, low & ahigh impedance state. This function is performed by 74LS244 IC.

Enable detector The main function of this block is to enable or disable the buffer IC by setting and resetting the active lowpins of buffer IC. It also consists of phototransistor and resistors.

Relay driver This block is performing the function of driving the relays. The device used here to drive the relay isULN2003 IC.

Relay A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magneticfield which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have twoswitch positions and most have double throw (changeover) switch contacts.

Power supply This section mainly consist of a transformer, rectifier circuit& voltage regulators. This section provides 5Vand 12V to the circuit elements.

Appliances This is the last stage that is, the output stage. This block consists of various appliances to be controlled.

4.CIRCUIT MODEL

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5.CIRCUIT DIAGRAM

6.CIRCUIT DESCRIPTION

The circuit presented here can be used as a lock for important electrical or electronic appliances. When cardis inserted inside its mechanism, depending upon the position of punched hole on the card, a particular appliance

would be switched on. The card is inserted just like a floppy disk inside the disk drive. This card should be

rectangular in shape with only one punched hole on it. The circuit uses four phototransistors when there is no card is

inserted in the lock, the light from incandescent lamp (40-watt, 230V) falls on all phototransistor detectors. The

fourth photo transistor is used as an enable detector for the buffer IC 74LS244. When light is incident on it, it

conducts and its collector voltage goes low. This makes transistor T16 to cut-off, and its collector voltage goes high.

This logic high on its collector terminal will inhibit the buffer IC as long as the light is incident on phototransistor T8.

Buffer IC will get enabled only when the card is completely inserted the lock mechanism. This arrangement ensures

that only the selected appliance is switched on and prevents false operation of the system. You can make these cards

using a black, opaque plastic sheet. A small rectangular notch is made on this card to indicate proper direction for

insertion of the card. If an attempt is made to insert the card wrongly, it will not go completely inside the mechanism

and the system will not be enabled. When card for any appliance (say appliance 1) is completely inserted in the

mechanism, the light will fall only on phototransistor T1. So only T1 will be on and other photo-transistors will be in

off state. When transistor T1 is on, its collector voltage falls, making transistor T9 to cut-off. As a result, collector

voltage of transistor T9 as also pin 2 of IC1 go logic high. This causes pin 18(o/p Q1) also to go high, switching

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LED1 on. Simultaneously, output Q1 is connected to pin 1 of IC2 for driving the relay corresponding to appliance 1.

Similarly, if card for appliance 2 is inserted, only output pin 16 of IC1 will go high, making LED2 on while at the

same time energizing the relay for appliance 2 via ULN2003. The same is true for other cases or appliances also.

By using this system we can control up to seven appliances at a time. This can be increased by increasing the

number of photo-transistor and replacing the ICs.

7.POWER SUPPLY

The present chapters the operation of power supply circuit built using filter, rectifier, and then

voltage regulators. Starting with an ac voltage, a steady dc voltage is obtained by rectifying the ac

voltage, then filtering to a dc level, and finally, regulating to obtain a desired fixed dc voltage .The

regulator is usually obtained from an IC voltage regulator unit, which takes a dc voltage, which remain

the if the input dc voltage varies, or the output load connected to the dc voltage changes.

The ac voltage, typically 220 v rms is connected to a transformer, which step that ac voltage

down to the level for the desired dc output. Diode rectifier then provides a full wave rectified voltage

that is initially filtered by simple capacitor filter to produce a dc voltage. This resulting dc voltage

usually has some ripple or ac voltage variation. The regulated circuit can use this dc input to provide a

dc voltage that not only has much less ripple voltage but also remain the same dc value even if the

input voltage vary somewhat, or the load connected to the output dc voltage changes. This voltage

regulation is usually obtained using regulator IC.

8.POWER SUPPLY DESCRIPTION

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VOLTAGE REGULATOR

The voltage regulator plays an important role in a power supply unit .The primary purpose of the

regulator is to aid the rectifier and filter circuit in providing a constant dc voltage to the device. Power

supplies without regulators have an inherent problem of changing of dc voltage values due to

variations in the load or due to fluctuations in the ac linear voltage. With regulator connected to the dc

output, the voltage can be maintained with a close tolerant region of the desired output.

IC VOLTAGE REGULATIOR

Voltage regulator comprises a class of widely use ICs. Regulator IC outs contain the circuit for

reference source, comparator, amplifier, control device, and overload protection all in a single IC.

Although the central construction of the IC is somewhat difference from that described for discrete

voltage regulator circuits, the central operation is much the same .IC units provides regulation of either

a fixed positive voltage, a fixed negative voltage or an adjustable set voltage.

A power supply can be built using a transformer connected to the ac supply line to step the ac

voltage to desired amplitude, then rectifying that ac voltage, filtering with a comparator RC filter, if

desired, and finally regulating the dc voltage using IC regulator.

The fixed voltage regulator has an unregulated dc input voltage, VI, applied to one input

terminal and a regulated output dc voltage, from a second terminal, with third terminal connected to the

ground. For a selected regulator, IC device specifications list a voltage range over which the input

voltage can vary to maintain a regulated output voltage. Over a range of load, current .The

specifications also list the amount of output voltage change resulting from a change in load current

(load regulation) or input voltage (line regulation).

Voltage Regulator O/p Voltage (Vo) Minimum I/p Voltage (Vi)

7805 5 7.3

7806 6 8.3

7808 8 10.5

7810 10 12.5

7812 12 13.5



Example of monolithic regulator s are 78xx/79xxseries and 723general purpose regulators.78xx series are three

terminal, positive fixed voltage regulators .In 78xx the last two numbers indicate the output voltage, the 7812 represent a

12 v regulator

The third IC terminal is connected to ground. While the input voltage may vary over some permissible voltage

range and the output load may vary over some acceptable range. The output voltage remains constant within specified

voltage variation limits

78xx series are three terminal positive fixed voltage regulators. There are some output voltage options available such as

5, 6, 8, 10, 12, 18and 24 V.

9.COMPONENTS

Part:-IC IC1 74LS244 1No. IC2 ULN2003 1No.

RESISTORSR1,R4,R7,R8 R17,R23,R29,R31 1K 8No.R3,R12,R15,R16 100K 4No.R18,R24,R30,R32 22K 4No.

CAPACITORSC3 1000Micro F 1No.C4 0.01Micro F 1No.C5,C6 47Micro F 2No.

TRANSISTORST1,T4,T7,T8 2N5777 4No.

T9,T12,T15,T16 BC109 4No.

DIODESD1,D2,D3 1N4007 3No.



RELAYRL1,RL2,RL3 12V,200ohm 3No.

10.COMPONENTS EXPLANATION

RESISTOR

A resistor is a two terminal electronic component that opposes an electric current by producing a

voltage drop in between its terminals in proportion to the current, that is in accordance with ohms law

:V=IR.The electrical resistance R=voltage drop V across the resistor divided by current I through the

resisitor. Resistors are used as part of electrical networks and electronic circuits

CAPACITOR

A capacitor is an electrical or electronic device that can store energy in the electric field between a

pair of conductors called plates.The process of storing energy in the capacitor is known as charging and

involves electric charges of equal magnitude, but opposite ,polarity, building upon each plate. Capacitors

are often used in electric and electronic circuits as energy storage devices. They can also be used to

differentiate between high frequency and low frequency signals. This property makes them useful in

electronic filters. Practical capacitors have series resistance, internal leakage of charge, series inductance

and other non-ideal properties not found in a theoretical, ideal, capacitor.

TRANSISITOR

An electrical signal can be amplified by using transistors that allows a small current or voltage to

control the flow of a much larger current. In analog circuit transistors are used in amplifier,(direct current

amplifiers, audio amplifiers, radio frequency amplifiers),and linear regulated power supply. Transistors are

also used in digital circuits where they function as electronic switches. Digital circuits include logic gates,

RAM, micro processors and dsp.

TRANSFORMER

Transformer is a device consisting of two or more coils used to transfer the electrical energy from one

circuit to another at different voltages without changing the frequency. It works on the principle of mutual

induction. Basically a transformer consists of two inductors having same core. It has two windings called

primary winding and secondary winding. When there is a change in current in primary winding a magnetic

flux is induced in the core. Since the core is common for secondary winding and also the magnetic flux

induce a voltage in the secondary winding. Transformers are used in rectifiers, audio applications and



amplifiers.

SEMI CONDUCTOR DIODES

Semi conductor diode is fabricated by joining together a P type and N type semi-conductor. So it is

also called as pn junction diode. It conducts current in one direction only. This property is used in rectifiers.

Silicon and germanium are most popular semi conductors. They have a common feature that outer most

shell of atom contains four electrons. In other words these atoms are tetra valent atoms type and N type

semi conductors are made by adding trivalent and penta valent atoms to the pure semiconductor

respectively. This process is called doping.

RELAY

A relay is an electrically operated switch. The current flowing through the coil of relay creates a

magnetic field which attracts a liver and changes the switch contacts. The coil current can be on or off so

the relays have two switch positions and most have double throw (change over) switch contacts.

Relays allow one circuit to switch a second circuit which can be completely separate from the first. There is

no electrical connection inside the relay between the two circuits; the link is magnetic and mechanical.

Many relays use an electro magnet to operate a switching mechanism, but other operating principles are

also used. When an electric current is passed through the coil, the resulting magnetic field will results in a

consequent movement of movable contacts.

PHOTO TRANSISTORS

The photo transistor used here is 2N5777.It is a silicon npn photo detector. It has high sensitivity. It is

more economical.

11.PCB SOLDER LAYOUT



12.PCB COMPONENT LAYOUT

13.PCB FABRICATION

The PCB manufacturing process involves use of expensive equipments, but homebrew PCB fabrication is

less expensive .It requires Intel Pentium PC,600-1200dpi laser printer with premium-quality paper or butter-paper

and miscellaneous items like single side copper laminated board, Lacquer thinner, sand paper and others. The

various steps involves in PCB fabrication are

1. PC-based artwork

2. Printing on a laser jet printer

3. Transfer of pattern to copper plate using cloth iron

4. Etching and Drying

5. Drilling and cleaning

6. Caution



1. PC BASED ARTWORK

The PC based artwork consists of drawing the conductor pattern. For putting artwork on the

component side of the board, flip the whole image before or while taking the print. When the pattern has been

drawn, take the print out in 600 to 1200 dpi on a translucent or butter paper. Keep the paper side on which the

toner is deposited facing down over the copper laminated boards copper side and then when the board is turned

component side up, the pattern on the conductor will be found properly aligned with the components. Finally we

take the printout of the PCB.

2. TAKING THE PCB LAYOUT PRINT USING A LASER PRINTER

Take the printout of the circuit layout from a laser printer. The idea is to use a coated paper so that the toner

comes loose when heated which would transfer a sharp black print on to copper laminate. Print for each of the

required layers should be taken on separate paper.

3. TRANSFER OF THE CONDUCTOR PATTERN

Scrub the copper side of the copper clad laminated used for the PCB board with a sponge. The scrubbing involves

removes oxidation, stains, etc. And it also makes the copper surface some-what rough which helps the toner to adhere to the

copper surface. The next step is to degrease the board thoroughly using a paper towel soaked with acetone solvent. Keep doing it

until no more discoloration is seen on the paper towel. Rub hard and keep switching to clean parts of towel. Place and align the

paper on the copper side, using an iron box to maximum setting on the back of the paper for at lest half a minute. If you don't apply

enough heat, the film or toner may no stick or be dark enough. The removal of paper from PCB is done by putting it into hot water

for 10 or more minutes. Check whether it has transferred properly onto copper plate.

Dig the bristles on the tip of a smooth tooth brush into the holes, remove the paper part from the tight areas like drill-holes.

Now cut the PCB to required size by using a hacksaw.

4. ETCHING

Etch the unwanted copper from the board using the ferric chloride solution for 20 or more minutes. One pint

can etch at least 3.6 sq. meters of the 28gm board. Heating the etchant will speeds up the etching process. The PCB

is attached to a wooden piece and dip in to the solution. Lift the PCB up and

Check whether all the unwanted copper is removed. Then it is immersed in to cold water to clean. When etching is

complete, board is removed from the solution and rinse it under running tap water .Acetone or lacquer thinner is

used to remove the toner .Lacquer thinner is used as a solvent in painting industry. Wash the board in lacquer thinner

solvent, rubbing with a paper towel, to remove the toner instantly.

5. DRILLING AND CLEANING



In this we had used a PCB hand drill .Use 0.8mm PCB drill bit to drill out all of the component holes. After

drilling the holes scrub sponge is used to clean before soldering .After drilling and cleaning, wash the board in cold

water and then dry it.

6. CAUTION

Lacquer thinner is extremely volatile, inflammable and explosive .Acetone can irritate eyes and respiratory

system .Ferric chloride is corrosive, so avoid skin and eye contact.

14.SOLDERINGSoldering is the process of joining metals by using lower melting point metal to wet or alloy with the joined surfaces. Solder is the

joining material. It melts below 427C. Soldered joints in electronic circuits will establish strong electrical connections between

component leads. The popularly used solders are alloys of tin and lead that melt below the melting point of tin.

In order to make the surfaces accept the solder readily, the component terminals should be cleaned chemically or by

abrasion using blades or knives. Small amount of lead coating can be done on the cleaned portion of the leads using soldering iron.

This process is called tinning. Zinc chloride or ammonium chloride separately or in combination are the most commonly used fluxes.

These are available in petroleum jelly as paste flux. A solder joint can at first glance to be okay, but under close examination it could

be a Dry Joint. A dry joint is when either the circuit board or the leg of the component has not been properly heated to allow the

solder to flow between the surfaces freely. This creates an intermittent or no electrical connection. This can also be caused by a

lack of flux or if you reuse old solder.

Quite often, reheating a bad join will cure the problem but in a lot of cases, the old solder will need to be removed and some new

solder applied. The residues, which remain after the soldering, may be washed out with more water, accompanied by brushing.

Soldering iron is the tool used to melt the solder and apply at the joints in the circuit. It operates in 230V mains supply. The

iron bit at the tip of it gets heated up within a few minutes. 50W and 25W soldering irons are commonly used for soldering

purposes.

PROCEDURE

1. Make a layout of the circuit.

2. Straighten and clean the component leads using blade or knife. Apply a little flux on the leads. Take a little



solder on soldering iron and apply the molten solder on the leads.

3. Mount the components on the PCB by bending the leads of the components using nose-pliers.

4. Apply flux on the joints and solder the joints. Soldering must be done in minimum time to avoid dry soldering

and heating up of components. Wash the residue using water and brush.

15.APPLICATIONS

We can use Electronic card lock system in industries where large amount of electricity is required.

16.ADVANTAGES

Provide securities in electronic or electrical devices.



Save electricity by controlling the use of devices. The devices can be easily controlled. The circuit can be implemented easily. The components can be easily available and cheap.

17,DISADVANTAGE Different card is used to control different devices.

18.FUTURE SCOPE



We can use the advanced version of card by using secret codes. It can be implemented using micro controller for adding more security features.

19.CONCLUSION

Our project Electronic card lock system is a humble contribution to the world of electronics. The present system of

controlling the electronic appliances using switches does not provide much needed security. But, our system provides

the much needed security, the appliances can only be controlled using the particular punched card.

Our system is less expensive, provides more effective security and is easy to implement. So we hope it will

be implemented extensively.



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1 comment:

saibabu Devulapalli 22 March 2013 at 06:11

which technology used for the Card Lock system ? tell me please

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