Design and Construction of A Tachometer
Design and Construction of A Tachometer
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ABSTRACT
Most electrical workshops which involves the use of motor to do a specific task lacks tools to
measure the exact speed at which the motor should rotate. Also, in generating station that
involves the continuous monitoring of the revolution per minute of a generator to avoid a change
in the frequency need a precise measuring tool to achieve that. Tachometer is a RPM
counter which counts the number of rotations per minute. There are two types of tachometer -
one is mechanical and the other one is digital. Here we are going to design an Arduino
based digital tachometer using IR sensor module to detect object for count rotation of any
rotating body. As IR transmits IR rays which reflect back to IR receiver and then IR Module
generates an output or pulse which is detected by the arduino controller when we press start
button. It counts continuously for 5 seconds.
.
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Table of Contents
LIST OF FIGURES...........................................................................................................................................5
CHAPTER ONE...............................................................................................................................................6
1.1 INTRODUCTION.................................................................................................................................6
1.2 AIM AND OBJECTIVES.......................................................................................................................6
1.3 SCOPE OF THE PROJECT....................................................................................................................7
1.4 PROJECT MOTIVATION......................................................................................................................7
1.5 METHODOLOGY................................................................................................................................7
1.6 PROBLEMS DEFINITION.....................................................................................................................8
1.7 PROJECT LIMITATION........................................................................................................................8
CHAPTER TWO............................................................................................................................................10
LITERATURE REVIEW..................................................................................................................................10
2.0 INTRODUCTION...............................................................................................................................10
2.1 HISTORY OF TACHOMETER.............................................................................................................10
2.1.1 REVIEW OF SIMILAR WORK.........................................................................................................11
2.2 REQUIRED COMPONENTS...............................................................................................................12
2.2.0 POWER SUPPLY UNIT..................................................................................................................12
2.2.1 BOOST CONVERTER.........................................................................................................................13
2.2.2 LITHIUM CHARGER......................................................................................................................14
2.2.3 ARDUINO MICROCONTROLLER..................................................................................................14
2.2.4 THE OUTPUT...............................................................................................................................15
2.2.5 PROXIMITY SENSOR....................................................................................................................16
2.2.6 LITHIUM BATTERY.......................................................................................................................18
2.2.7 RESISTOR.....................................................................................................................................19
CHAPTER THREE.........................................................................................................................................21
DESIGN METHODOLOGY............................................................................................................................21
3.0 PROJECT SPECIFICATION.................................................................................................................21
3.1 CIRCUIT OPERATION.......................................................................................................................21
Power Supply..............................................................................................................................................23
CHAPTER FOUR...........................................................................................................................................24
DESIGN IMPLEMENTATION AND TESTING..................................................................................................24
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4.0 PROJECT RESOURCE CENTERS.........................................................................................................24
4.1.1 CHOICE OF MATERIALS...............................................................................................................24
4.2 DESIGN IMPLEMENTATION STEPS..................................................................................................24
4.2.1 COMPONENT LISTING.................................................................................................................25
4.3 DESIGN STEPS.................................................................................................................................25
4.3.1 Component placing and wiring...................................................................................................26
4.3.2 COMPONENT SOLDERING...........................................................................................................26
4.4 INSERTING THE IC INTO THE HARDWARE DESIGN..........................................................................26
4.5 CIRCUIT TEST...................................................................................................................................26
4.6 PACKAGING.....................................................................................................................................27
4.7 DESIGN TEST AND ERROR CORRECTIONS........................................................................................28
4.8 FINAL TEST......................................................................................................................................28
CHAPTER FIVE.............................................................................................................................................29
RECOMMENDATION AND CONCLUSION....................................................................................................29
5.0 SUMMARY......................................................................................................................................29
5.1 PROBLEM ENCOUNTER...................................................................................................................29
5.2 SUGGESTION FOR FURTHER DESIGN...............................................................................................30
5.3 RECOMMENDATION.......................................................................................................................30
5.4 CONCLUSION..................................................................................................................................30
REFERENCE.................................................................................................................................................32
4
LIST OF FIGURES
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CHAPTER ONE
1.1 INTRODUCTION
Power many phases of industrial and commercial operations, it is frequently necessary to measure
ways, depending on the nature of the object to be measured. One of such methods to achieve this
is by the use of a tachometer. A tachometer is an instrument that measures the rotational speed of
a shaft or disk, as in a motor or machine. The word is derived from two Greek words tachos
(“speed") and metron ("measure") [2]. It works by the same principle as a tachogenerator, which
produces the voltage according to the velocity of the shaft. By measuring the voltage produced by
a tachogenerator, you can easily determine the rotational speed of whatever it is mechanically
attached to. Its operation can be electromagnetic, electronic or optical-based. The speed of the
electric motor is determined by the number of revolutions made by the motor in one minute. Thus
a tachometer is also known as revolution-counter, and has the same unit as speed--revolution per
minute (RPM)[2].
The aim of this project is to design and construct a digital base tachometer using an infrared
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2. To develop a monitoring system that shows the results of the rpm on an LCD screen
The design of this device is limited at producing to just the construction and implementation of a
Most of this equipment are not locally gotten especially by engineering institutions in Nigeria.
They are expensive to buy and often import from foreign countries. Their designs are simple and
easy to construct but the packaging is actually what attracts engineers. Therefore, this motivate
me to develop a tachometer device using materials gotten from our local environment.
1.5 METHODOLOGY
Though there are several ways by which a digital tachometer could be designed, we choose this
method which makes use of a microcontroller as the main control unit of the device [11], infrared
transmission technique as the detection mechanism, an alphanumeric LCD module for display
and a proximity sensor[8] for detection of the rotation of the shaft whose speed is being
measured. In these case of these the counted pulses will come from the proximity sensor, which
will detect any reflective element passing in front of it, and thus will give an output pulse for each
and every rotation of the shaft. Those pulses will be fed to the microcontroller and counted. The
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.
In laboratories and workshops, these equipment are mostly used to carry out practical especially
when used with trainers, the speed or revolution per-meter of a generator may be required to
perform a specific function. And even in auto mechanic workshops where they often employ use
of engine or generator speed and in power plant where a certain speed of the turbine need to be
ascertain before the generator is activated, but before then, a tachometer is used to measure the
speed.
This is a theoretical circuit is limited to just small system powered by one lithium cell and other
mini components. This work makes it possible for someone to use one power supply to run
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different devices of higher or lower voltage rating without considering buying a new or different
power supply.
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CHAPTER TWO
LITERATURE REVIEW
2.0 INTRODUCTION
This chapter carried a conceptual discourse of power supply auto switching system and
established the relationship between them. It also reviewed some literature in a field of study to
Furthermore, a theoretical frame work to properly situate the study was presented.
2.1HISTORY OF TACHOMETER
The first Tachometer is widely considered to have been developed by the German engineer,
Dietrich Uhlhorn in 1817. Uhlhorn needed a gauge to measure the speed of machines. Little did
he know that within 200 years this simple device was going to be a standard feature on vehicles
driving in every continent on the Earth. The Tachometer is an instrument that measures the
rotation speed of a shaft or disk. It is also known by several other terms including a rev-counter
and RPM gauge. The gauge usually displays the revolutions per minute (PRM) on a calibrated
analogue dial. On a vehicle, such as a Car or Motorcycle, the Tachometer measures the rate of
rotation of the engine's crankshaft. With a Tachometer, driver's are able to assess the 'engine
speed' and change the gearing ratio accordingly. Each Tachometer indicates the maximum RPM
for that particular engine. Exceeding this limit may result in either engine damage or total failure.
A tachometer is a device used to measure rotational speed of a machine. This device usually
displays the rotational speed in revolutions per minute (RPM) on a digital display, traditionally on
an analogue display. The word tachometer comes from Greek Ταχος, tachos, which means speed
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and metron which means to measure. The first documented use of a tachometer was by an
engineer named Dietrich Uhlhorn in 1817, who is the assumed inventor. No one is sure of who
invented the first tachometer [1] but it was based on measuring the centrifugal force, comparable
to the centrifugal governor shown in figure 1. Figure 1 shows a self-regulating device for
controlling the flow rate of a liquid. The first tachometer used the centrifugal force of the balls
which moved outwards as they rotated (driven by steam in a pipe) and was attached to an
indicator or needle that showed the speed. Later it was used to measure the speed of locomotives
in 1840. [2]. Tachometers are needed in modern times to measure the rotational speed of
numerous things. It is advantageous to know the duration of time and the speed of a moving
object then the distance can be calculated and maintenance can be scheduled to prevent wear and
tear. The most common tachometers are used in vehicles to determine speed and distance. There
are many ways to measure rotational speed and this thesis will present the method used to make a
tachometer and some problem encountered while building one. The speed of detection of the
The first mechanical tachometer was similar in operation to a centrifugal governor. The inventor
of the first mechanical tachometer is assumed to be a German engineer Dietrich Uhlhorn; he used
it for measuring the speed of machines in 1817. Since after then, it has been used to measure the
speed of locomotives in automobiles, trucks, tractors and aircrafts. Early tachometer designs were
based on the principle of monostable multivibrator [13], which has one stable state and one
quasistable state. The circuit remained in a stable state, producing no output. However, when it
receives triggering current pulse from the ignition system, the circuit transitions to the quasistable
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state for a given time before returning again to the stable state. This way, each ignition pulse
produced a clean pulse of fixed duration that was fed to the gauge mechanism. The more of such
fixed duration pulses the gauge received per second, the higher it read.
Lithium battery
Lithium charger
Resistors
LM7805
Proxoity sensor
Arduino microcontroller
switches
Capacitors k convert
The power system is powered by one lithium battery which can serve over a week without being
drained down completely. The power supply consist of a lithium battery, the charger and the dc to
dc boost step-up converter to step up the voltage to 5V as since virtually all the sub-section of the
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Lithium
Lithium Cell DC-DC boo
charger
A boost converter (step-up converter) is a DC-to-DC power converter that steps up voltage
(while stepping down current) from its input (supply) to its output (load). It is a class of switched-
mode power supply (SMPS) containing at least two semiconductors (a diode and a transistor) and
at least one energy storage element: a capacitor, inductor, or the two in combination. To
reduce voltage ripple, filters made of capacitors (sometimes in combination with inductors) are
normally added to such a converter's output (load-side filter) and input (supply-side filter). Boost
converters are highly nonlinear systems and a wide variety of linear and nonlinear control
techniques for achieving good voltage regulation with large load variations have been explored. [1]
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2.2.2 LITHIUM CHARGER
The Li ion charger is a voltage-limiting device that has similarities to the lead acid system. The
differences with Li-ion lie in a higher voltage per cell, tighter voltage tolerances and the absence
of trickle or float charge at full charge. While lead acid offers some flexibility in terms of voltage
cut off, manufacturers of Li-ion cells are very strict on the correct setting because Li-ion cannot
accept overcharge. The so-called miracle charger that promises to prolong battery life and gain
extra capacity with pulses and other gimmicks does not exist. Li-ion is a “clean” system and only
it has similar functionality to the Arduino uno, but in the DIP module package and works with a
Mini-B USB cable. Is also a Arduino clone which is perfectly compactible with Arduino IDE
(Integrated Development Environment). The technical specifications of the Arduino Nano board
is that is uses a microcontroller ATmegaa328, with operating voltage 5v, input voltage 6-20v, 14
digital IO(Input and Output) pins of which 6 provide PWM output, 8 Analog input pins, flash
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memory 32kb while 2kb used by bootloader, 2kb SRAM, 1kb EEPROM, 16MHz clock speed
and 0.73” x 1.70” dimensions. The Arduino Nano can be powered via the Mini-B USB
connection of which the sketches from the IDE are uploaded also, 6-20v unregulated external
Liquid Crystal Display screen is an electronic display module and finds a range of applications, A
16x2 LCD display is very basic module and is very commonly used in various devices and circuit
as used in irrigation system. These modules are preferred over seven segments and other multi
segment LEDs. The reasons being LCDs are economical and easily programmable, have no
limitation of displaying special and even custom characters, animations and so on.
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16x2 LCD means it can display 16 characters per line and there are 2 such lines. In this LCD each
character is displayed in 5x7 pixel matrix and has two registers namely, Command and Data. The
command register stores the command instructions given to the LCD. A command is an
instruction given to LCD to do a predefined task like initializing it, clearing its screen, setting the
cursor position, controlling display etc. The data register stores the data to be displayed on the
LCD. The data is the ASCII value of the character to be displayed on the LCD. Click to learn
The A proximity sensor is a non-contact sensor that detects the presence of an object (often
referred to as the “target”) when the target enters the sensor’s field. Depending on the type of
proximity sensor, sound, light, infrared radiation (IR), or electromagnetic fields may be utilized
by the sensor to detect a target. Proximity sensors are used in phones, recycling plants, self-
driving cars, anti-aircraft systems, and assembly lines. There are many types of proximity
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sensors, and they each sense targets in distinct ways. The two most commonly used proximity
sensors are the inductive proximity sensor and the capacitive proximity sensor.
An inductive proximity sensor can only detect metal targets. This is because the sensor utilizes an
electromagnetic field. When a metal target enters the electromagnetic field, the inductive
characteristics of the metal change the field’s properties, thereby alerting the proximity sensor of
the presence of a metallic target. Depending on how inductive the metal is, the target can be
Capacitive proximity sensors, on the other hand, are not limited to metallic targets. These
proximity sensors are capable of detecting anything that can carry an electrical charge. Capacitive
sensors are commonly used in liquid-level detection. Possible targets for capacitive sensors
include but are but not limited to: glass, plastic, water, wood, metals, and a myriad of targets of
other materials.
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2.2.6 LITHIUM BATTERY
The A lithium-ion battery or Li-ion battery is a type of rechargeable battery composed of cells in
which lithium ions move from the negative electrode through an electrolyte to the positive
electrode during discharge and back when charging. Li-ion cells use
typically graphite at the negative electrode. Li-ion batteries have a high energy density,
no memory effect (other than LFP cells)[9] and low self-discharge. Cells can be manufactured to
prioritize either energy or power density. [10] They can however be a safety hazard since they
contain flammable electrolytes and if damaged or incorrectly charged can lead to explosions and
fires.
M. Stanley Whittingham discovered the concept of intercalation electrodes in the 1970s, and
invented the first rechargeable lithium-ion battery, which was based on a titanium disulfide
cathode and a lithium-aluminum anode, patented in 1977, and assigned to Exxon.[11] John
Goodenough expanded on this work in 1980 by using lithium cobalt oxide as a cathode.[12] A
prototype Li-ion battery was developed by Akira Yoshino in 1985, based on the earlier research
by John Goodenough, M. Stanley Whittingham, Rachid Yazami and Koichi Mizushima during
a Sony and Asahi Kasei team led by Yoshio Nishi in 1991.[15] Lithium-ion batteries are
commonly used for portable electronics and electric vehicles and are growing in popularity for
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.
2.2.7 RESISTOR
a circuit element. Resistors 220Ω, 10kΩ, and 1kΩ were used in this project to reduce current
flow, and at the same time, act to lower voltage levels within circuit.
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Figure 9 Resistors 1KΩ, 10KΩ and 220Ω.
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CHAPTER THREE
DESIGN METHODOLOGY
3.0PROJECT SPECIFICATION
This is the design and construction of a tachometer for electrical laboratories and workshops. This
project uses microcontroller as the main control unit of the device [11], infrared transmission
technique as the detection mechanism, an alphanumeric LCD module for display and a proximity
sensor[8] for detection of the rotation of the shaft whose speed is being measured. In these case of
these the counted pulses will come from the proximity sensor, which will detect any reflective
element passing in front of it, and thus will give an output pulse for each and every rotation of the
shaft. Those pulses will be fed to the microcontroller and counted. The result will then be
3.1CIRCUIT OPERATION
The As shown in the above tachometer circuit, it contains Arduino Pro Mini, IR sensor module,
buzzer and LCD. Arduino controls the whole process like reading pulse that IR sensor module
generate according to object detection, calculating RPM and sending RPM value to LCD. IR
sensor is used for sensing object. We can set sensitivity of this sensor module by inbuilt
diode which detects or receives infrared rays. IR transmitter transmits infrared rays, when these
rays fall on any surface, they reflect back and sensed by photo diode (You can understand more
about it in this Line Folloewr Robot). The output of photo diode is connected to a comparator,
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which compare photo diode output with reference voltage and result is given as output to arduino.
IR sensor module output pin is directly connected to pin 18 (A4). Vcc and GND are connected to
Vcc and GND of arduino. A 16x2 LCD is connected with arduino in 4-bit mode. Control pin RS,
RW and En are directly connected to arduino pin 2, GND and 3. And data pin D4-D7 is
connected to pins 4, 5, 6 and 7 of arduino. A push button is also added in this project. When we
need to count RPM we press this button to start this Arduino Tachometer to count RPM for five
seconds. This push button is connected to pin 10 of arduino with respect to ground. You can learn
more about the working of IR transmitter and receiver circuit in this circuit .
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Power Supply
The system operates at 12V and 5V with low power consumption. Batteries could be used to
provide the energy required by this device. But also a regulated power supply (220/240V AC,
The basic functions in a regulated power supply are transformation, rectification, filtering and
regulation. [3]
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CHAPTER FOUR
This includes:
The materials used were from the information gotten from the internet and the work was
developed through the source gotten online that was treating the same case.
The circuit diagram used is the diagram which was design as a prototype but also works to revive
some information about the circuit analysis of the devices which later entered more design like
the Potentiometer sensor that was well tested and ensured is adjusted based on the value
prescribed.
Care was taken while soldering the connections any mismatch or carelessness will easily fry your
components. Ordinary solders might not be able to withstand 3A, this will lead eventually melt
your solder and cause short circuit. Use thick copper wires or use more lead while connecting the
high current tracks as shown in the picture. Any short circuit or weak soldering will easily burn
your transformer windings; hence check for continuity before powering up the circuit. For
additional safety fuse on Input side can be used. High current voltage regulators mostly come in
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metal can packages, while using them on dot board do not place components close to them as
their body acts as the output of the rectified Voltage, further will result in ripples. Also do not
solder the wire to the metal can, instead use a small screw as shown in the picture given below.
Solders don't stick to its body, and heating results in damaging the Regulator permanently. Do not
skip any filter capacitors from the schematics, this will damage you Arduino. Do not overload the
transformer more than 3A, stop when you hear a hissing noise from the transformer. It is good to
operate between the ranges of 0 - 2.5A.Verify the output of your 7812 before you connect it to
your Arduino, check for overheating during first trial. If heating occurs it means your Arduino is
consuming more current, reduce the backlight of the LCD to solve this.
a. Proximity sensor
b. Resistors
c. LED
d. Lithium battery
e. Lithium charger
i. LCD
j. Jumper wires
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4.3 DESIGN STEPS
These are the various steps we took on the design of this project.
Here, the whole components were place into the Vero board according to its position in the
circuit diagram, the legs were bend to avoid living its space and to avoid it from failing off.
The components were solder using a soft thick lead oxide and the component connections was
done with a tiny flexible wire we got from a networking cable to join one component to the other
Then after that the IC will now be inserted into the circuit for testing.
4.5CIRCUIT TEST
After the implementation of the circuit diagram it has to be powered and checked for accurate
functionality before coupling and packaging. The design makes use of a lithium battery with a
capacity of 4.2V and 5000mAH that can last for over 7 days.
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Figure 12 system test
4.6 PACKAGING
As a prototype design, we have to copy an existing system which was based on timing.
The packaging was done on a predefined modeling designed by an architect. And placement of
all sections of the circuits were done together with the LED display using glue gum, araldite and
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4.7 DESIGN TEST AND ERROR CORRECTIONS
After the packaging some errors was discovered due to wrong packaging which affected the
reading by the Potentiometer sensors taking random readings to cause the display to read
wrongly, but was corrected. Below is the work during testing and correction.
4.8FINAL TEST
The final test was undergone for proper function and design usage. As shown in the diagram
below.
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CHAPTER FIVE
5.0 SUMMARY
This section of this project report forms the concluding part of the write up and takes a look at
some of the problems encountered during the progressive job on the system and also brings in
suggestions for further improvement and/or enhancement for the system design since the
construction was limited to just voltage alone, a current sensor could be added to measure the
The design and development of this project has really been challenging, as I have been faced with
choices far beyond what I expected. But in the long run the result paid off.
After the complete design of the system, the deviation between the expected result and the actual
result was very close. The performance and efficiency was beyond expectation and from every
5.1PROBLEM ENCOUNTER
During the course of the design of this system, there were series of problems which came in the
way of achieving the design goals of this project, most of them where over come via share
troubleshooting, in some cases some part requires redesigning and debugging also created a bit of
a problem especially the placement of the proximity sensors which randomly adjust itself from
One major setback of this project is the availability of components required to build the hardware
of the system. In most cases I had to look through electrical catalogs to obtain replacements of
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The final packaging of the design was also another trouble, as this actually caused problems on
the circuit board. Such problems include partial contact within the circuit board, between
components and also with the wiring. This was actually one of the most challenging aspects of
the circuit implementation phase. Due to this fact, there was a lot of soldering and de-soldering to
It will be more appreciated if the system is designed for switching AC load. And also with the
rise in the need of higher rated solid devices like MOSFET, Thyristor, Triacs and even Relays,
5.3RECOMMENDATION
b. Supply the necessary voltage to the system by plugin its power mains to 200v to 230v
ac.
5.4 CONCLUSION
However in generating station that involves the continuous monitoring of the revolution per
minute of a generator to avoid a change in the frequency need a precise measuring tool to achieve
that. Tachometer is a RPM counter which counts the number of rotations per minute. There are
two types of tachometer - one is mechanical and the other one is digital. Here we are going to
design an Arduino based digital tachometer using IR sensor module to detect object for count
rotation of any rotating body. As IR transmits IR rays which reflect back to IR receiver and then
30
IR Module generates an output or pulse which is detected by the arduino controller when we
31
REFERENCE
[1]. Belone Schilling, Electronic Circuits: Discrete and Integrated, McGraw-Hill, New
York,1979.
[2]. B.L Theraja and A.K Theraja, A Textbook on Electrical Technology, 2003, 23 rd Edition, Pp
1887 – Pp 1888.
[3]. Paul Horowitz and Windfield Hill, The Art of Electronics, 1989, 2nd Edition, Pp 7- Pp 8, Pp
[4] W.C. Mann, ‘Smart technology for aging, disability and independence : the state of the
[5] R. Antunes, ‘Intruder alarm systems: the state of the art’, Proceeding of the 2ND International
Conference on Electrical Engineering, 2007, pp. 251-261. ISBN 972-99064-4-2. [3] M. Griffiths,
‘Smart Home Security: Home building & Renovating’, ABI Research Mobile, 2008.
[6] P. Schertz, ‘Practical Electronics for Inventors’, Mc Graw Hills, 2nd edition, 2000, ISBN- 0-
01-058078-2
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