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Design and Development of Low Cost Auto Gate System for House Part 5
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FULL REPORT
DESIGN AND DEVELOPMENT OF LOW COST AUTO GATE SYSTEM
FOR HOUSE
NAME MATRIC NO
FOO CHUN YANG MA12088
SIEW MUN KIT MA12087
LOO KIAN SING MA12086
ABDUL HADI BIN SHAMSUL KAMAR MA12100
MUHAMMAD IKHWAN BIN RAZAK MA13001
1.0 INTRODUCTION
The idea of using Auto Gate is not new, but the cost of installing the system is
expensive. In their work, home automation system was proposed that included home appliances
and devices that are controlled and maintained in home management. Their major contribution
to knowledge was to improve home automation, with considering the low cost of budget.
The major purpose of this project is to design and develop a new auto gate system with
a low cost. In order to have the desired secured area, the use of a computer system are employed
to set up a novel controller which operates the gate depending on the signals received from the
processed input parameters such as the control of the gate using either a remote control.
In this study, in order to design the low cost auto gate system the components used are:
mild steel, power window motor, motor driver, Arduino, and others. The system which is the
design and construction of an automatic sliding door was designed considering some factors
such as economy, availability of components and research materials, efficiency, compatibility,
portability and also durability. The performance of the system after test met design
specifications. The general operation of the system and performance is dependent on the
presence of the person entering through the door and how closer he/she is to the door. Also the
operation is dependent on how well the soldering is done, and the positioning of the
components. In general, the system was designed, and the real time implementation was done
with a prototype of the model. The speed of the opening and closing of the door which is able
to be controlled for the ease of the user. Last but not least, the range of the Bluetooth control
system is also determined.
The idea of using Auto Gate is not new, but the cost of installing the system is expensive.
In some projects, home automation system was proposed that included home appliances and
devices that are controlled and maintained in home management, which provide an automatic
selective remote control of computer system components that facilitates conserving electrical
energy while providing the capability of controlling the system from a central location [1, 2].
A problem with expanding use of control systems technology to distributed systems are the
costs associated with the sensor-actuator infrastructure required to monitor and control
functions within such system [3]. Thus, the major contribution to knowledge was to improve
communications system and processing capability of the home automation [4-8], with
considering the low cost of budget by selecting suitable infrastructure [9, 10].
Automatic gate is an automated movable barrier installed in the entry of a room or building
to restrict access, provide ease of opening a door or provide visual privacy [21, 22]. It provides
microcontroller to control devices thereby reducing the work of a man [23-25]. In some of the
projects, an automation device system is developed to control the automatic gate as well as
integrating android phone application [26]. Nowadays automatic sliding gate has wide range
of use. Its special feature is that it has rollers which help to slide on defined rack. It reduces
friction and makes handling easier [21, 27-31].
Switch which is one part of this work may be the most ubiquitous mechanical devices in
our technological society [32-35]. Most every machine needs to be turned on or turned off at
some point, and that's typically done by activating a switch. Mercury switches are used rarely
nowadays, and they should be disposed of using hazardous waste protocols due to the high
toxicity of metallic mercury in the environment [28, 36-39]. The switches used in automated
gate nowadays are commonly controlled by using Arduino system.
Arduino is an open-source computer hardware and software company, project and user
community that designs and manufactures microcontroller-based kits for building digital
devices and interactive objects that can sense and control objects in the physical world. The
project is based on microcontroller board designs, manufactured by several vendors, using
various microcontrollers [3, 40-45]. These systems provide sets of digital and analog I/O pins
that can be interfaced to various expansion boards ("shields") and other circuits. The boards
feature serial communications interfaces, including USB on some models, for loading
programs from personal computers [10]. For programming the microcontrollers, the Arduino
project provides an integrated development environment (IDE) based on
the Processing project, which includes support for the C, C++ programming languages [41, 46-
48].
This research comprises both analog circuits and digital circuits. The system has both
security application and luxury, since it is more comfortable and easy if the opening and closing
of the door are done automatically [49]. The system could be done and implemented in the
building of school, house and various departmental buildings.
3.0 METHODOLOGY
This chapter shows an effective method to achieve the objectives of the project.
Start
Satisfied?
YES
Sketch Drawing
NO
Satisfied? Modification of the
Design
YES
Purchasing of Materials and Devices
Needed
A
A
Modification of NO
Satisfied? Execute the Program
the Gate System
Troubleshoot
Success? NO
the Problem
YES
YES
Assembling of the
Mechanical and
Electrical Parts
NO
Success? Modification
YES
End
This project was started with literature review after identify the problem statement with
the title ”Design and Developement of Low Cost Auto Gate System for House”. The journal
related to this project were investigated and compared in order to decide the most suitable
materials and devices for fabrication and design of an auto gate system. After the selection of
the materials and devices needed, the auto gate system was first sketched and then was designed
by using the Solidworks. Modification of the design was done to make sure the design meet
the conditions needed. The materials and devices were then obtained by purchasing from
suppliers online, hardware shop and lecturer. Fabrication and assembling of the gate system
and the arduino setup were done at the same time. Modification was made to improve the
design structure and artistic of the design. The program with Arduino was executed and
troubleshooting was made to meet the desired output. After finished operated those processes,
mechanical parts and electrical parts were assembled together for the integration of gate system
with Arduino Programming system. The result of the opertaion of auto gate system were then
obtained and the discussions were listed down. At the end, the final report was double checked
before final submission.
3.2 MATERIALS
Mild steel is also considered as low carbon steel which has excellent weldability and
produces a uniform and harder case. It had been chosen for the material of the gate due to its
good balance of toughness, strength and ductility. The mild steel hollow tubes were obtained
from FKM Raw Material Store after the appointment and agreement from the staff, En. Muhd
Hafietz. While the sheet metal was obtained from the FKM mechanical lab.
3.2.2 ALUMINIUM
Aluminium had been used as the material for the connector shaft for the purpose to
coneect the gear and the motor. It had been chosen due to its light weight and its ability as a
shaft to reduce vibration. A solid cylindrical aluminium specimen was obtained.
3.3 MACHINES
The model of the cutting machine is 355mm (14”) (Quick Lock Vise) High-Speed Cut-
Off Machine. It has sturdy aluminium housing and double insulated. It has soft grip handle and
easy to operate D-handle. It is spark diversion guard and it has spindle lock. It had been used
to cut the hollow tubes into several parts with desired dimensions. It has a power input 2200W
and no load speed of 3800/min. It has a maximum working peripheral speed of 4800m/min. It
was used to cut the mild steel tubes. 45 degree was cut at the edge of some tubes by this cutting
machine for the ease of the welding process.
The model of the shielded metal arc welding machine is Dialarc 250 AC/DC Stick
Welder. It has a ampere range of 20 DC to 150 DC. It was selected to weld the joints of the
tubes to form gate due to some factors. The process of arc welding is fast and reliable, moreover
it is an inexpensive power source and relatively inexpensive equipment. Several welding rods
were used when conducting the welding process.
3.3.4 LATHE MACHINE
Pinacho S-90 180-1000 Lathe 415V is the model which rotates the workpiece on its
axis toperform various operations suc as cutting, drilling,turning and others with tools that are
applied to the workpiece to create an object which has symmetry about an axis. It has a splindle
speed range of 30 to 2000 rpm with main power of 2.2 to 3.4kW. It was used to make the
desired shape of the connnector shaft from the solid cylinder aluminium specimen.
The vertical milling machine used has a brand of Milltronics with model VMM-3917
and it has a maximum spindle speed of 4000rpm with 5HP motor. Milling machine is used to
made a slot on the connector shaft to fix the position of the connector shaft when connected
with the gear.
3.3.7 BENDING MACHINE
The MTP Hydraulic Press Brake Bending Machine is a machine tool for bending sheet
and plate material, most commonly the sheet metal. It forms predetermined bends by clamping
the work piece between a matching punch and die. This machine includes multi-axis computer-
controlled back gauges for accurating a correct position for metal. It was used to bend the mild
steel sheet metal.
Two V-Guild wheels were used and attached to the gate to reduce the frictional force
between the gate and the floor.Thus, the gate can move more effectively.
3.4.2 BOX
Vertical rollers were used as a bearing to guild and smooth the movement of the gate
in one axis either to the right or left.
Switching Power Supply Adapter 12V with 15Amp was used as the power supply for
the motor driver and power window motor. It has a power supply unit of 180 Watt power. It
has 2 slot for V+ and 2 slot for V-. Its dimension is 200mm x 100mm x 42mm. It is a device
that converts attributes of one electrical device or system to those of an otherwise incompatible
device or system.
3.5.2 ARDUINO SET
Arduino UNO – R3 is the Atmega328 microcontroller board used for our project. It has
an input woltage range of 7 to 12V with 14 digital I/O pins and 6 analog inputs. It has 32k flash
memory and 16Mhz clock speed. It is an microcontroller-based kits when designed and
manufactured to start, stop and control the direction of the dc motor rotates. This
microcontroller board provide sets of digital annd analog input and output pins that can be
interfaced to various expansion boards and other circuits.
HC-06 Bluetooth Module is the model used as a serial port bluetooth for our project. It
is for drop-in replacement for wired serial connections, transparent usage. It is a bluetooth
protocal with bluetooth specification v2.0+EDR. It has a frequency of 2.4GHz ISM band with
modulation of GFSK (Gaussian Frequency Shift Keying). It has a Class 2 emission power with
less than 4dBm and sensitivity of less than -84dBm at 0.1% BER. Its speed is asynchronous
with 2.1Mbps maximum/ 160kbps and synchronous with 1Mbps/ 1Mbps. Its security is based
on authentication and encrytion. Its power supply is around +3.3VDC 50mA with working
temperature of -20 to +75 Centigrade. Its dimension is 26.9mm x 13mm x 2.2mm. We used it
simply for a serial port replacement to establish connection between smart phone and the
embedded project.
Power window motor is an electric component, need the help of a small electric device
to power its linkage. The coupling had customized that fit prefectly to power window motor
can further be attach to gear with just 3 screws. It has a 12V DC voltage rating with no load
speed of 85 rpm. It requires a current of less than 3A with no load, and less than 7 A with load.
It has a torque of 30kg.cm. It was controlled by the Arduino Programming designed to rotate
clockwise or anti-clockwise which produce the right amount of torque to move the gate.
3.5.4 MOTOR DRIVER
MD10C Motor Driver was used for our project. It has bi-directional control for 1
brushed DC motor which support motor voltage ranges from 5V to 25V. Its maximum current
can up to 13A continous and 30A peak for 10 seconds. It has 3.3V and 5V logic level input. It
is a solid stae componetns provide faster response time and eliminate the wear and tear of
mechinical relay. It has fully OS H-Bridge for better efficiency and no heat sink is required. Its
speed control PWM frequency can up to 20kHz which the actual output frequency is same as
input frequency. It supports both locked-antiphase and sign-magnitude PWM operation. It is
also a little current amplifier which is used to take a low current control signal and then turn it
into a higher current signal that can drive a motor.
3.5.5 BREADBORD
Jumper wires which are short electrical wires with a solid tip at each end was used in
our project to interconnect the components of the electronics system.
3.5.7 WIRE
We had used some wires for the connections between the electrical and electronics
components or devices.
3.6 TOOLS
We used metal file to remove the residues formed on the edges of the tube after the
shearing process by grinding machine.
We had bought the devices and components needed for this project. The total amount
of the price for those items were around RM 502.36. Table 3.7 shows the price and number of
each device or component.
Table 3.1: Price and number of the items used
1) Raw material, mild steel tubes were cut into few parts by cutting machine with desired
dimension and cutting angle.
2) The cut tubes were then joined together to form gateframe and gate supporting system
by shielding metal arc machine.
3) Two vertical rollers were attached to the gate supporting system and to horizontal
rollers were attached at the bottom of the gate frame.
4) Sheet metal was formed by the shearing machine and attached to the gate frame.
5) Rack was then attached to the bottom side of the gate frame.
6) A aluminium connector shaft was made by lathe machine which connect the gear and
the motor. Three holes were made by drilling machine at the flange of the shaft. A slot
was made by the vertical milling machine on the connector shaft.
7) Power window motor and gear were mounted together with connector shaft by 3
screws. They were then installed at the bottom side of the gate support system.
8) Railway was embedded with the gate supporting system at the base.
9) The welding residues were then removed by grinding process.
10) The whole resembled system was then painted in order to provide a protection layer to
the mild steel which easily rusted.
11) Electronic system is then mounted together to the resembled whole system.
12) The entire auto gate system for house was set up as shown in the figure below.
10) A system was designed at the smart phone’s application, Roboremo as shown at the
figure above for the controlling of gate’s movement.
4.0 CALCULATIONS
The length of the gate and the total track length has been measured using measuring tape.
Figure 4.1 shows different lengths of the gate system that have been taken.
Figure 4.1: Gate length and the track length of the auto gate
The speed of the power window motor is 85rpm and it is converted to unit radian per second
as below,
85 × 2𝜋
= 8.9023 𝑟𝑎𝑑/𝑠
60
𝐷 = 𝑉𝑡
𝐷
𝑡=
𝑉
0.9
=
0.3116
= 2.8885 𝑠
= 2.9 𝑠
𝑉 = 0.4𝑟𝜔
= 0.4 × 0.0035 × 8.9023
= 0.1246 𝑚𝑠 −1
The time for the gate to fully open which is to travel the distance D = 0.9 m at constant speed
V=0.1246ms-1 is
𝐷 = 𝑉𝑡
𝐷
𝑡=
𝑉
0.9
=
0.1246
= 7.2231 𝑠
= 7.2
Percentage of Error
Theorical
Experiment
18
16
14
Time Taken (s)
12
10
1 2 3 4 5 6 7 8 9
Speed (rad/s)
20
0
1 2 3 4 5 6 7 8 9
Speed (rad/s)
Range in Working
One of the main objectives of the research papers is to determine the time taken for the
gate to fully open and close. In this section, the time taken for the gate to close and open fully
have been calculated theoretically and later determined experimentally. The process to record
the time taken to fully close and open the gate is by using a stopwatch. Once the ‘open’ button
of the interface is pressed, the stopwatch was started. Just when the gate reached the end, the
stopwatch was stopped. Fig 10 shows the completed product.
The objective of determining the range of distance for the Bluetooth control system to operate
has been achieved. The range of distance has been determined by operating the smartphone
interface at different distances. Table 4.1 shows the result of the test. From the results shown
in the table, we can conclude that the bluetooth device of the smartphone apps interface is able
to operate within the range of 30 meters.
From figure 10 and 11 above, the percentage error for motor travelling at full speed will
decrease when the speed increase. This is probably due to the motor is initially gaining speed
to accelerate from 0 to 0.1246 ms-1 when travelling at 40% speed. As a result from this, the
time taken for the motor to reach constant speed has been increased and hence the percentage
error is larger compared to motor travelling at full speed.
6.0 RECOMMENDATION
There are few recommendations to improve our auto gate system. The first
recommendation is we can design the auto gate system so that it can be open automatically by
using interface on the smartphone and also manually by pushing or pulling of the gate frame
by our own hand. The way to install the gear is the main key to this recommendation. We can
design a moveable power window motor with gear in which it can be rotate 120 degree
anticlockwise. Thus, even the auto system cannot function, we still can able to rotate the
position of the power window motor with gear to move it away from matching the rack and
pinion, and so we can open the gate manually.
Another recommendation is we can make it more automatically. We can install limit switch
which is attached to the both sides of the gate frame. Coding can be edited so that the gate can
be opened or closed by pressing the button on the interface one time only, instead on keep
pressing the designed button. When the gate is opened or closed, each limit switch will be
switched on and the automatic movement can be stopped. This can further reduce the time used
by the user to open and close the gate, from keep pressing the button to pressing one time only.
7.0 CONCLUSION
We have achieved all our objectives from firstly designed an auto-gate system with a
1.25m x 1.6m gate dimension that can work fluently when it operates. The speed of the auto-
gate can also be adjusted so that it is suitable for all users to decide their desired speed for all
purposed. Besides, we also determined the approximate working range for the Bluetooth
system for the auto-gate system to create a new generation of keyless auto-gate system that
controlled by cell-phone applications.
APPENDIX
GANTT CHART:
ASSEMBLYING PARTS
REPORT PREPARATION
EXHIBITION
PLANNING
ACTUAL
REFERENCES
#include <SoftwareSerial.h>
int bluetoothTx = 0;
int bluetoothRx = 1;
int forward = 9;
char cmd[100];
int cmdIndex;
void exeCmd() {
if(cmd[0]=='f')
analogWrite(backward, 0);
analogWrite(forward, 100);
if(cmd[0]=='b')
analogWrite(forward, 100);
analogWrite(backward, 100);
if(cmd[0]=='c')
{
digitalWrite(backward, LOW);
digitalWrite(forward, HIGH);
if(cmd[0]=='g')
digitalWrite(forward, HIGH);
digitalWrite(backward, HIGH);
if(cmd[0]=='k')
digitalWrite(backward, 0);
digitalWrite(forward, 0);
void setup() {
delay(500);
pinMode(forward, OUTPUT);
digitalWrite(forward, LOW);
pinMode(backward, OUTPUT);
digitalWrite(backward, LOW);
bluetooth.begin(9600);
bluetooth.print("$");
bluetooth.print("$");
bluetooth.print("$");
delay (250);
bluetooth.println("U,9600,N");
bluetooth.begin(9600);
cmdIndex = 0;
void loop() {
if(bluetooth.available()) {
char c = (char)bluetooth.read();
if(c=='\n') {
cmd[cmdIndex] = 0;
exeCmd();
cmdIndex = 0;
else {
cmd[cmdIndex] = c;
if(cmdIndex<99) cmdIndex++;