A REPORT

ON

DIGITAL TESTER:
TESTER DIGITAL INVERTER FOR DIGITALISATION

BY

BHARATH M 20171ECE0041
LIBITA BONACHAN 20171ECE0146
SONAM PAL A 20171EEE0064

AT

LEOCH BATTERIES INDIA PVT LTD

Professional Practice Centre of

PRESIDENCY UNIVERSITY, BENGALURU

(JULY, 2019)

1
 A REPORT

ON

DIGITAL TESTER:
TESTER: DIGITAL INVERTER FOR DIGITALISATION

BY

BHARATH M 20171ECE0041 ECE

LIBITA BONACHAN 20171ECE0146 ECE
SONAM PAL A 20171EEE0064 EE
EEE

Prepared in partial fulfillment of the

PIP 101,Professional
Professional Practice – I

AT

LEOCH BATTERIES INDIA PVT LTD

A 53(B),2nd Main Road, Peenya 2nd stage, Industrial area, Bangalore - 560058
Professional Practice Centre of

PRESIDENCY UNIVERSITY, BENGALURU

(JULY,
JULY, 2019)
2019

2
 DECLARATION

I hereby declare that the report entitled “DIGITAL TESTER: DIGITAL INVERTER FOR DIGITALISATION"
which is being submitted to the Presidency University, Bangalore is a bonafide report of the work
carried out by me / us. The material contained in this report has not been submitted to any
University or Institution for the award of any degree. I also declare that this report does not contain
any confidential information of the Organization.

BHARATH M 20171ECE0041 ECE

LIBITA BONACHAN 20171ECE0146 ECE

SONAM PAL A 20171EEE0064 EEE

3
 ACKNOWLEDGEMENTS
“Presentation inspiration and motivation have always played a key role in the success of any venture.”

We are thankful to our institute,'' PRESIDENCY UNIVERISTY '' thus allowing us to do a professional and
technical project.

We are also thankful to LEOCH BATTERIES INDIA PVT LTD for allotting a project to us in electronics and
communication and for providing all the necessary inputs for our project.

We would like to express our gratitude to Prof.Dr. Satish Babu Boppana, for his precious contribution
in bringing this project to life.

We take this opportunity to thank our co-guide Mrs. Mary J, Mr. Adil A S our project advisor for
continuously educating and guiding us throughout this Endeavour.

We are deeply indebted to Dr.B.V.Prabhu for his constant support and mentorship.

We would also like to thank each and everyone in the digital design, department for their consistent
guidance and encouragement.

Our parents are also an important inspiration for us .So with due regards, We express our gratitude's
to them.

Last but not the least, we are grateful to each and everyone involved directly or indirectly in this
project, for their valuable inputs and support.

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 PRESIDENCY UNIVERSITY, BENGALURU
Professional Practice Program
Professional Practice (IP) – I

PP Centre: LEOCH BATTERIES INDIA PVT LTD

Start Date:10th June 2019 End Date: 2nd August 2019

Title of the Project: DIGITAL TESTER: DIGITAL INVERTER FOR DIGITALISATION

Name of the Student ID No. Branch

BHARATH.M 20171ECE0041 ECE
LIBITA BONACHAN 20171ECE0146 ECE
SONAM PAL A 20171EEE0064 EEE

Name of the Expert Designation Department

Mr .ADIL A S DGM SERVICE
MARY J DIRECTOR PAN INDIA

Name(s) of the PP Faculty: Dr.SATISH BABU BOPPANA

Key Words: Batteries, Inverter, Current Sensor, Digital Display, Storage Device and Jumper Wires

Project Areas: DIGITAL TESTER

Abstract:

Modern society is interlinked through a network of not only people, but their respective electronic
devices as well. The devices permeate people’s lives so thoroughly that it is rare to see someone
without an electronic device, be it a watch, a cell phone, a computer.

Yet, these devices have not even touched the surface of what is possible.
Recent research has delved into so called “Smart” devices. These smart devices are ordinary,
everyday gadgets that together with sensors widely broaden the possibilities of what is capable.
However, there are just as many types of sensors as there are electronic devices.

5
To communicate with each of these sensors through custom hardware is an expensive and tedious
process. Hence, there is a need for a system that can flawlessly connect different sensors and make
sense of this data.
We have developed an open source microcontroller on in which charging and discharging cycles are
sensed. Our design creates a cheap and easy interface in which it can be connected with all the
Home Inverters.

Signature(s) of Student(s) Signature of PP Faculty

Date: Date:

6
 Table of Contents

Content Page no

ACKNOWLEDGEMENTS
ABSTRACT
Chapter 1 – Introduction 8
Section 1 - Company Profile 8
Section 2 - Introduction to the Project 9
Chapter 2 - Solution Exploration and Selection 10
Section 1 - Flow Diagram 10
Section 2 - Charging and Discharging Cycles 11
Section 3 - Budget 12
Chapter 3 - Technical Work Performed 14
Section 1 - Hardware Design Efforts 14
Section 2 - Hardware Implementation 15
Section 3 - Software Implementation 18
Subsection 1 - Microcontroller Program 18
Chapter 4 - Testing 22
Section 1 - Hardware Testing 22
Section 2 - Software Testing 22
Chapter 5 – Work Schedule 23
Section 1 - Final Prototype 23
Section 2 - Cost 23
Subsection 1 - Prototype Cost 23
Subsection 2 - Production Cost 23
Section 3 – Schedule 23
Chapter 6 – Conclusion 24
Recommendation
References

7
 Chapter 1 – Introduction

Section 1 –Company Profile

LEOCH International Technology Limited, founded in 1999,specializes in the research, development,

manufacturing and sales of the globally renowned LEOCH brand lead acid batteries. LEOCH is an
International new technology corporation launching stock successfully on Hongkong main board
(LEOCH International 00842.HK). After years of innovation, LEOCH has become a leading manufacturer
of lead acid batteries and the largest lead acid batteries exporter in China.

LEOCH enterprise consist of three production factories located in Jiangsu, Guangdong and Anhui in
China, and two abroad in Malaysia and Sri Lanka.

It covers an area of nearly 910,000 square meters, with 70 battery production lines and corresponding
testing machines, two research and development centers in Guangdong and Jiangsu.

Today, LEOCH has over 10,000 employees, more than 400 experienced researchers and technicians
worldwide. LEOCH has mainly produce AGM, Start and Motive Power types, including AGM VRLA
battery, Gel battery, ENERPURE, UPS High Rate batteries, Marine batteries, Railway batteries, Start-
Stop batteries, OPzV , OPzS , PzB PzS tubular plate batteries, automotive battery, motorcycle battery,
golf cart battery, Scrubber Sweeper batteries, electric vehicle battery. These products are widely used
by many different industries, such as telecommunication, power system, radio and television system,
railway, solar, UPS electric vehicles, cars, golf cars, forklifts, emergency lights, security, alarm,
gardening tool, baby carrier etc. Annual gross production value exceeds 20 million KVAh.

8
Section 2 – Introduction to the Project

Within the last few decades, there have been major advancements in power
electronics. Power electronics have moved along with developments with such things
as digital signal processors being used to control power systems .For each and every
battery there is a particular charging and discharging cycles which are not known to
the customers and service providers.

There is no such technology which can read number of charging and discharging
cycles. This idea has not come into the mainstream because of the lack of awareness
in the concepts. Thus, the report briefly describes the process involved of knowing
the charging and discharging cycles of the battery.

9
 Chapter 2 – Solution Exploration and Selection

Section 1 – Flow Diagram

The complete system design with its logical components is more easily presented by utilizing the
Flow diagram. The Flow diagram is able to take what could possibly be a complicated project and
break it down to an easy to follow format. Having a recognizable format such as this enables the
designer to best focus their efforts on what is needed in the final product. The Flow diagram
developed by the team is shown below.

Figure 2.1 - Flow Diagram

The Sensor Interface can be broken down into three main components: The microcontroller, ,the
sensor and the digital display which it communicates with. Microcontroller and the digital display
are essentially the support behind the sensor to collect, store, transfer and display data. Designing
more advanced sensor was beyond the scope of this project, so the Microcontroller and the digital

10
display became the areas of focus. Once the microcontroller has logged data from the current
sensor, it stores the data via a microSD card. Storing the data in with an onsite microSD card has
several advantages, most of which that it allows for minimal power consumption by not constantly
transferring the data to the digital display. Logging data in this way allows the microcontroller to
store data for weeks or months without any communication to the digital display if desired. Once
the data is wanted, simply connecting the laptop to the microSD card will transfer the data to the
laptop once the digital display is launched. From there , the laptop can display the data and use it as
the user sees fit.

Section 2 - Charging and Discharging Cycles

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Section 3 – Budget
We planned a standard budget of Rs.500 for completion of the project.
project. As shown in the information
informat
below, the team used Rs.480
Rs.480 out of Rs.500
Rs.500 to construct the prototype. Beyond this, a few items for
display purposes were donated by team members and our sponsors. The software chosen for design
was open-sourced
open sourced or free.

The budget summary table and pie chart of purchased expenditures is shown below:
Software: Hardware:
PCB Design Rs.0 Sensors:
Android IDE Rs.0 Purchased: Rs.250
Logistics: Microcontroller :
Handing Charges : Rs.30 Arduino Nano Rs200
Purchased Total: Rs.48
Rs.480

Table 2.3.1 - Budget Summary

Software Hardware Logistics Microcontroller

Figure 2.3.2
2.3 - Purchased Product Expenditures

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Arduino Nano
ano 200 Acs712 current 150
sensor
MicroSD 100 Battery (12V 7.2AH) 790
Module
200W Bulb 60 Inverter 4,500
Full Production Cost Rs.5800

Table 2.3.3 - Final Production Costs

Arduino nano
Acs712 current sensor
microSD module
Battery (12V 7.2AH)
200W Bulb
Inverter

Figure 2.3.4 - Final Production Expenditures

13
 Chapter 3 – Technical Work Performed

Section 1 – Hardware Design Efforts

The Sensor Interface’s hardware requirements include a microcontroller, an SD card module,
Inverter and a battery. The microcontroller is responsible for collecting connected sensor readings,
altering sensor parameters, and transferring sensor readings to the other hardware components
when necessary. It must be able to read analog sensors. The SD card module’s role is to provide a
large memory space to store sensor readings over long periods of time, our minimum requirement
was set at one hour. This module should both write to an SD card and read from an SD card when
required. The team’s proposed solution was to design a microcontroller that included all of these
parts on one board so that it can remain small and efficient in design.

Designing this product in the EASYEDA software takes careful planning and time to continually
adjust where traces through the board will be routed. EASYEDA contains a large number of
components in premade libraries. These built-in parts covered nearly everything needed to add to
the design, however some of the more specific components had to be added to the design manually.
The current sensor and micro SD shield were the only two parts not already included in the libraries.
To get these designs to populate in the same space as the rest of the board the files had to be
imported from manufacturer websites which required use of the professional version of the
software. These are imported as separate schematics but can be edited simultaneously with the
main schematic and attached by using labels instead of wires to join the different ports. Even with
separate schematics the physical layouts are represented in the same board layout page. Once all of
the components are populated into the board they needed to be manually arranged in the board
space we allocated, this was 6'' by 3'' for the original prototype. In order to fit all of the components
in the through hole style careful arrangement of parts was needed on both the top and bottom of
the board, this proved to be a challenge when routing traces as the bottom is typically reserved for
routing only. Routing traces can begin by using the auto-route function built into EASYEDA. This
however will not make every connection necessary for the board to function if it cannot find an easy

14
path from point A to B. With the remaining connection a path must be manually connected along
with wires to connect the ports from the different components.

Section 2 – Hardware Implementation

The microcontroller used is an Arduino Nano, shown in Figure 3.2.1. This is a popular
microcontroller that is easy to wire and program. It has sufficient analog input ports to read from
various analog sensors simultaneously, and also features a Serial Data (SDA) line and a Serial Clock
(SCL) line. Both an SDA line and an SCL line are required to support I2C sensors. With these input
ports, the Arduino Nano is able to read from two digital sensors simultaneously. Furthermore, the
Arduino Nano includes Serial Peripheral Interface (SPI) functionality, which allows it to interface with
certain peripheral hardware devices, such as SD card modules. On top of this, the board also allows
digital ports to be configured to act as Serial Receive (RX) or Serial Transmit (TX) lines.

Figure 3.2.1 - Arduino Nano

Sensing and controlling current flow is a fundamental requirement in a wide variety of applications
including, over-current protection circuits, battery chargers, switching mode power supplies, digital
watt meters, programmable current sources, etc. One of the simplest techniques of sensing current
is to place a small value resistance (also known as Shunt resistor) in between the load and the
ground and measure the voltage drop across it, which in fact, is proportional to the current flowing
through it. Whereas this technique is easy and straight forward to implement, it may not be very
precise because the value of the shunt resistor slightly varies with its temperature, which in fact is
not constant because of the Joule heating. Besides, this simple technique does not provide an
isolation between the load and current sensing unit, which is desirable in applications involving high

15
voltage loads. Today, we will talk about Allegro ACS712 device which provides an economical and
precise way of sensing AC and DC currents based on Hall-effect. This discussion is divided into two
parts. The first part will provide a brief overview of the ACS712 sensor and its characteristics. In the
second part, a test experiment will be carried out to interface the sensor with a PIC microcontroller
to measure a dc current.

Figure 3.2.2 ACS 712 Current sensor Module

Figure 3.2.3 - Microcontroller - ACS 712 Current sensor Module Connectivity

Figure 3.2.3 depicts the connections between the ACS 712 Current sensor Module and the
microcontroller. The module has a 5.0V input pin and a GND pin. The ACS 712 Current sensor
Module Analog pin is connected to analog pin on micr0controller.

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 Figure 3.2.4 -SD Card Module

The connections between the SD card module and the microcontroller can be seen in Figure 3.2.3.
The SD card requires both a 5V and a 3.3V supply to consistently operate correctly. During testing,
only the 5V pin was connected, which resulted in correct SD accesses only every other time. This
problem was corrected by connecting the 3.3V pin to the microcontroller’s 3.3V output as well.

The SD card module requires connections to the microcontroller’s SPI pins. These are the Arduino’s
P11, P12, and P13. P11 is the Arduino’s Master In Slave Out (MISO) pin, P13 is its Serial Clock (SCK)
pin, and P12 is its Master Out Slave In (MOSI) pin. These connect to the SD card module’s
corresponding pins. Furthermore, The SD card module needs a connection for Chip Select (CS),
which tells it whether or not it can communicate with the microcontroller. The default pin for this on
the Arduino Nano is P10.

Figure 3.2.5 - Microcontroller - SD Card Module Connectivity

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Section 3 – Software Implementation

Subsection 1 – Program

#include <SD.h>
#include <SPI.h>

File sdcard_file;
int v;
int v1;
const float vp=0.00488; // 5/1024
float voltage;
float current1;
float current;
int CS_pin = 53;

void setup() {
Serial.begin(9600);

pinMode(CS_pin, OUTPUT);

// SD Card Initialization
if (SD.begin())
{
Serial.println("SD card is ready to use.");
} else
{
Serial.println("SD card initialization failed");
return;
}

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 Serial.print("I ");

Serial.println(" ");
sdcard_file = SD.open("data.txt", FILE_WRITE);
if (sdcard_file) {
sdcard_file.print("I ");

sdcard_file.println(" ");
sdcard_file.close(); // close the file
}
// if the file didn't open, print an error:
else {
Serial.println("error opening test.txt");
}
}

void loop() {
v = analogRead(A0);
v1 = v-506;
voltage = vp * v1;
current1 = voltage/0.066;
current = abs(current1);
Serial.print("I:");
Serial.println(current);

sdcard_file = SD.open("data.txt", FILE_WRITE);

if (sdcard_file) {

sdcard_file.print(" I ");
sdcard_file.println(current);
sdcard_file.close(); // close the file }

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 // if the file didn't open, print an error:
else {
Serial.println("error opening test.txt");
}
delay(3000);
}

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 Figure 3.3.1 - Program Execution (Current reading)

Figure 3.3.2- Graphical Representation of Current vs Time

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 Chapter 4 – Testing

Section 1 – Hardware Testing

The ability to test the capability of the hardware and software was important to the results of the
project. Being able to test the hardware however is a difficult task as many of the tests of the
hardware and software are a binary result, either it works or it doesn’t work. This makes the real
test data for the team ,the reliability of the different components being used.

Creating a reliable product that will consistently work as desired is an obstacle of designing a
product from scratch. In order to accomplish this goal, thorough research had to be done for
separate portions of the products. The most popular modules were used due to their affordability
and accuracy/reliability for the price.

One such module that was ordered was for the project was the Arduino Nano module to allow
communication between ACS712 current sensor and MicroSD card.

Section 2 – Software Testing

Software testing included more testing of reliability and after reaching certain points in the project
began to have constant working expectations, meaning that the developed software would always
work after the initial testing had been finished. There were two different pieces of software to be
tested and so each had to be subjected to different requirements and tests. These software aspects
were the Arduino Microcontroller code that controlled the data flow of the sensors. When adding
and removing sensors in the interface, many issues could arise.

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 Chapter 5 – Work Schedule

Section 1 - Final Prototype

During the course of PP-1, a successful prototype for the Sensor Technology Interface, as well as
designs for both the final printed circuit board. The Arduino Nano microcontroller, as well as various
sensors were used. A wide range of sensors were tested, including analog sensors both wired, as
well as sensors using different protocols. However, the final prototype will showcase a digital
readings of current.

Section 2 - Cost
Subsection 1 - Prototype Cost
The project cost consisted of sponsored and purchased hardware. The total sponsored amount
totals Rs.5350, and the total purchase amount totals Rs.480. This cost includes sensors and
microcontrollers which are used in the final prototype.

Subsection 2 - Production Cost

The projected cost will be Rs.5800. This costs includes the manufacturing of the printed circuit
board, the price of the individual parts, and the price of assembly.

Section 3 – Schedule
This project was ambitious, and it was determined part way through the PP-1 that others would
most likely follow the work done by the team at a later date. The software and hardware side of our
project has been for the most part successful.

Section 4 – Findings
The final prototype consists of a It also includes a variable size SD card that can provide more than 1
hour of buffered input. All sensors use the analog input pins. Furthermore, the device can run on a
battery.

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 Chapter 6 – Conclusion
 The main scope of this project is to provide knowledge about the quality of battery.
 Digital Tester allows user to know about the lifespan of the battery in advance.
 Future improvements in wireless technology offer world changing implications
 This project is low-cost, reliable, effective and efficient system

Recommendation
 The Digital meter can be made even more advance with the use of more accurate
sensors and technology.
 Future improvements in our project will be wireless technology of transferring data

References

 ACS712 current sensor, working of current sensor [online] ACS712: Fully Integrated, Hall-
Effect-Based Linear Current Sensor IC with 2.1 kVRMS Voltage Isolation and a Low-
Resistance Current Conductor available from
www.allegromicro.com/en/Products/Current-Sensor-ICs/Zero-To-Fifty-Amp-Integrated-
Conductor-Sensor-ICs/ACS712.aspx

 Power Inverters , introduction to power inverter [online] taken from

en.wikipedia.org/wiki/Power_inverter

 Arduino Nano, datasheet of Arduino nano [online] is available from

wiki.eprolabs.com/index.php?title=Arduino_Nano

 MicroSD card module, How to connect sd card module to Arduino mega

wiki.eprolabs.com/index.php?title=SD_Card_Module

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 Circuit Diagram of Digital Inverter

Final Prototype of Digital inverter

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