Practical PIC Projects

 

 

F1 Gantry
 Race Start Lights
(version 3)

 


 


Description

Featured in Electronics Weekly Gadget Freak (15/08/2008)


The Control board for this project is now available in kit form or fully assembled and tested.
Please visit the Picprojects on-line shop for more details


This project provides an simple F1 motor racing style 5 light race start sequence with a fixed or random delay that you can use on a real race track, kart circuit or even your slot-car circuit. 

Operation is simple; when the start button is pressed all the LED clusters are off. They then illuminate sequentially until all five LED clusters are on.  After a timed interval that can be either fixed or random depending on requirements the LEDs extinguish, signalling the start of the race.  Once the LEDs have extinguished simply press the start button again to initiate another race start sequence.

The latest version of firmware allows all the timings and the random delay to be customised to suit individual requirements.  We've also added an output that can be used to trigger timing software or operate a relay, sounder or other device when the start lights extinguish.

New from August 2012 is the ability to abort the start countdown sequence.  This feature has been requested by a number of people since the project was first published.

With the new 'abort' feature, pressing the start button again at anytime during the countdown will immediatly set the outputs to a fixed pattern indicating the start has been aborted.  This fixed pattern remains displayed until the start button is pressed and held for over 1 second at which point the controller resets ready for a new start.   The feature can be disabled at the time of purchase if it is not required.

This page presents a complete application using 52mm (2" inch) diameter LED clusters, but the software in the PIC microcontroller has been written to allow it to operate electro-mechanical relays, large arrays of LEDs, low voltage lamps, or even simply small 3/5/8 or 10mm LEDs.

 


Operation photo's

Power-on

When the circuit is first powered on the outputs do the following.

2 seconds

Only appears if Start switch input is active
(switch pressed)
LED's will stay in this state until Start
 switch is released.

8 seconds
(or Start switch pressed)

Start sequence

When the start switch is pressed and released the first output turns on followed by the next four outputs. Default timings set the interval between each LED turning on  at 1 second but this can be customised.

After the fifth output has been on for 1 second, the controller starts a random delay that will last anywhere from 0 to 4 seconds at which point all outputs are turned off.  Again the duration of the random delay can be changed to suit requirements, or it can be set to a fixed period.

Once a start sequence has completed, simply press the start button again to initiate another start.

Photo showing operation with 2 rows of 5 LED clusters
(built on prototype during development)

 

Raceway Karting


Timing and Modes

August 2012

Update: This kit is now shipping with Firmware V4 which supports an 'abort start' function.


The 'abort start' function is very simple to operate, using the same switch used to trigger the start countdown sequence.

After the switch has been released to trigger the start sequence it can be pressed again at any time during the countdown to abort the start.

If the start is aborted a fixed pattern is immediatley displayed on the light outputs.  This can only be cleared by holding the start switch down again for over 1 second resetting the controller ready for a new start.

If this feature isn't required you can request to have it disabled when ordering a kit or programmed PIC.

Timing and mode options are held in the PICs EEPROM.  These values can be set when the PIC is programmed.  If you have access to a PICkit2 programmer the values can also be re-configured by the end user.  PICs supplied in the kit will have default timings set.  If you want customized timings you can provide us with a list of time values for each parameter shown in the timing data and we will pre-program them into the PIC supplied with the kit.

Modes and Timing and abort-function details

Display modes

The outputs can operate in either bar or dot mode.

Timing Data

The timing diagram  shows all the parameters that can be configured.  These can be set from 0 to 25.5 seconds in 100mS intervals

Default timings and mode supplied in the kit.

 0    ; light mode value, 00 bar, >00 dot
 0    ; pre-light hold time value x 100mS [TP]
 10   ; light 1 on time value x 100mS [TL1]
 10   ; light 2 on time value x 100mS [TL2]
 10   ; light 3 on time value x 100mS [TL3]
 10   ; light 4 on time value x 100mS [TL4]
 10   ; light 5 on time value x 100mS [TL5]
 40   ; end hold delay value x 100mS (or maximum random time)[TH]
 0    ; end mode value.
      ; 0 for random end delay
      ; >0 for fixed end delay

 5    ; start gate output time value x 100mS [TSTC]
      ; If TSTC= 0, start gate output is always on except when
      ; start sequence is active

 41   ; b'00010101'  abort hold light state.
 1    ; 0 - abort feature not enabled
      ; 1 - abort function enabled

The above timings summarised are:

  • 5 lights illuminating in bar mode at 1 second intervals.
  • 0-4 second random delay at the end.
  • Start gate output is active for 0.5S
  • Abort function is enabled and displays '0-0-0' pattern on light outputs

For step-by-step guide to editing and reprogramming the EEPROM timing data see here


Circuit description

The circuit described on this page is designed around Kingbright's 52mm LED cluster module which comprises 50 red LEDs in a waterproof housing with a brightness in excess of 16000mcd.  In the original version of this project each LED cluster was directly driven and all those LED's required a hefty current with the ten LED cluster version requiring a power supply capable of delivering over 2amps at 12V DC.

The input power to the board can be fed from either the DC Jack or 2-way screw terminal block.  These connectors are wired in parallel to give a choice of connection.  The positive supply is fed to the rest of the board via D1 which provides protection against a reversed power connection to the board.  D1 is a Schottky diode and is used in preference to a standard diode because of its a low forward voltage drop of around 0.25 volts.  A 78L05 voltage regulator provides the 5 volt supply for the PIC and a ULN2003A interfaces the PIC outputs to the LED modules.  LED1 is connected across the output of the 78L05 to provide a power-on indication.

The start switch input connects to the PIC via R3,R4 and C3 which provide immunity to false triggering from electrical noise.  If the start switch is located more than a couple of metres from the control PCB it is advisable to use the isolated switch input which offers greater protection against both false triggering and spikes on the input.

The controller also includes an optional isolated switch input.  This uses an CNY17 opto-coupler which provides an electrically isolated trigger input for the controller. This allows the start to be triggered from another device such as a computer timing system.  It also provides electrical isolation for safety reasons, or can be used to reduce the possibility of false triggering in an electrically noisy environment.  Resistor R6 provides current limiting for the LED inside the CNY17 and D2 protects against reverse connection of the power to the isolated input.

The LED modules are driven by a ULN2003A darlington transistor array.  The board supports two rows of 5 LEDs with each row using a single current limit resistor (R1/R2).  The LEDs are driven with a PWM signal to allow adjustment of the overall brightness.  Since all the LEDs in one row share a single current limit resistor, the LEDs are driven one at a time.  This means only one LED module is ever actually on but the output scans at ~350Hz so they appear to be on simultaneously.  As mentioned above, this reduces the current requirements from just over 2amps for a 10 LED setup to under 500mA.  If only a single row of LED modules are used this drops to around 260mA.

The brightness of the LED modules can be adjusted using potentiometer PR1.  This feeds a voltage between 0 and 5 volts to the PICs internal analogue to digital converter.  The digitised value is then used to adjust the duty cycle of the PWM output to the LED modules. 

JP2 provides a timing start gate output for external equipment.  This is an open-collector output that is driven low for a fixed duration at the completion of the LED start sequence.  This can be used to trigger an external timing system, release a start gate, or drive another LED cluster.  Additional circuitry may be required depending on the specific application.  Since it's primarily intended to trigger another device or system at the end of the timing sequence this output is not driven with a PWM signal.  If it's used to drive a LED module, the brightness isn't adjustable using PR1. 

Circuit Schematic

 

 

 

Schematic

Board connections

Power input

Power can be supplied to the board either through the DC Jack connector or the 2-way screw terminal block.  These connectors are wired in parallel so if the DC Jack is used for the power input, the 2-way screw terminal connector can be used as an auxiliary DC output if required.  The board requires a 12 volt DC supply rated for a minimum of 300mA for a single row of LED clusters or 600mA for a dual row.   A 13.8 volt supply can also be used (see here)

LED Clusters

The board supports either a single row of LED cluster modules or two rows.  For use with a single row connect the five LED cluster modules to column A header pins.  For a two row LED cluster setup connect the first row to Column A header pins and the second row to Column B header pins.

The connector from LED cluster modules has a red and white wire attached.  The Red wire should be connected to the An pin of the 2-pin header, the white wire to the Ca pin as indicated by the PCB overlay text.

Input option 1

Input option 2

Input option 3

Start Switch input

There are a several options for connecting the start switch to the board.  There is a direct connection input and also an opto-isolated input.  The isolated input can be used where the switch is a long way from the board, or in electrically noisy environments.  It can also be used to trigger a start sequence from a computer or other equipment.

Input option 1.
If the start switch will be located within a couple of metres of the board, use the non-isolated switch option.  The switch is connected directly to the CN2 input of the board.

Input option 2
Use input option 2 if the switch will be located more than a couple of metres from the board, or in an electrically noisy environment.  With this option the power for the isolated input comes from the input power to the board.  The opto-isolator prevents noise and spikes from false triggering or damaging the microcontroller.  This option doesn't require a second power source for the isolated input since it shares the input power to the board.

Input option 3
Use input option 3 if you need to trigger the start sequence from other equipment such as a computer or you need to keep the controller electrically isolated.  This option keeps the electrical power for the two systems completely isolated. 

S1 Test switch
The S1 test switch fitted to the PCB can be used to trigger a start sequence with or without an external switch / isolated switch connected to the board.   Useful for testing the board at assembly time and troubleshooting during normal use.

For more detailed information see the 'Operating notes' section


Parts List

A complete kit of parts, including the PCB can be bought from the Picprojects on-line shop.   The kit includes the parts listed.  It does not include the LED cluster modules or power supply.

Parts Listing

The LED Cluster, power supply and a suitable start button switch can all be sourced from Rapid Electronics and delivery is free on orders over 30.  The part numbers to order are shown below.

Description Part # Qty
52MM ULTRABRIGHT LED CLUSTER (RC) 56-2985 5 (10)
LRG RED PUSH TO MAKE SWITCH (RC) 78-1550 1
15W MINIPLUG TOP PSU 12V DC1.2AMP (RC) 85-2902 1

The Kingbright LED clusters are also available from a other UK Suppliers

 


Construction notes

Construction details for the PCB version are presented in pictures below.  The assembly is fairly straightforward however a few components do need to be installed the correct way round.  Read through the whole of this section before starting assembly, then refer to it during assembly.

Unpopulated PCB.  The white markings are the component overlay.  This shows where to fit the components and in some cases which way round to fit them.  Follow it carefully.

Start by installing the resistors
See resistor colour code guide

Diodes D1 and D2 must be fitted the correct way round.  Each diode has a band around one end.  They should be installed with the band matching the component overlay as shown

Now install the capacitors.  C4 must be installed the correct way round.  One lead is longer than the other; this is the positive lead.  On the PCB overlay you will see a small '+' symbol next to one hole.  The long lead should be fitted through this hole, the short lead through the other.

Install LED1 with the short lead nearest the corner of the board as shown in the photo.

 

Install the 78L05 voltage regulator with the flat face matching the component overlay as shown. You will need to bend the centre lead back slightly to fit the holes in the PCB.

    

Fit resistor R1 and R2.  Once they are soldered in place carefully trim the wire leads.
These wires should be used to make the four wire links LK2, LK3, LK4 and LK4 (photo right)
(n.b. you can actually use any of the component lead off-cuts for these links)


There are two IC sockets which should be installed into positions IC1 and IC2. These have a small notch in one end, align the notch with the marking on the overlay.

Install PR1, S1, and IC3.  The board should now look like the one above.

 

 

When installing IC's 1,2 and 3 make sure they are fitted the correct way round.  The body of the chip has a notch in one end (arrowed above).  The chips must be fitted with the notch as shown. Also check the pins don't get bent under the device instead of going into the hole/socket.

Finish off by installing the 2-pin headers, screw terminal blocks and the DC Power Socket.  Fit the nylon PCB spacers using the M3 screws. The board should now look similar to the one above

 

On the underside of the board there are some exposed copper tracks.  These should be tinned with solder as the photo shows.  While you're doing this inspect the board for poor solder joints, solder splashes etc. and correct them. 


Completed board

If you have a multimeter to hand, we suggest you remove IC1 from its socket.  Apply 12 volts to the input power connector.  If LED1 lights, measure the voltage between pins 1 and 14 of the IC1 socket.  This should measure 5 volts +/- 0.25 volt.

Race Start Controller Test Rig (back)

Race Start Controller Test Rig (front)

Operating notes

DC Power input

The board needs a DC regulated input of 12 volts. This should be rated for at least 300mA for a single row of LED clusters or 600mA for a dual row.  The circuit will only draw the current it needs so if you have a power supply rated for higher current, as long as its output is 12 volts, this will be ideal.

If you wish to use a 13.8 volt power supply replace D1 (1N5417) with two 1N4001 diodes in series.  (If you're buying the kit and you intend to use a 13.8 volt supply, let us know when you place the order and we'll supply a pair of 1N4001 instead of the 1N5417)

Do not use an unregulated DC power supply as these generally only deliver the specified voltage at full load. 

As the board has no fuse or over current protection, this should be provided externally.  Typically a regulated DC power supply will have overload protection built-in and if this is the case nothing further is required.  If you power the circuit from a battery or other source then you must ensure there is a suitable in-line fuse.

The DC Jack and 2-pin screw terminal block are connected in parallel. Either connector can be used.  If power is applied through the DC Jack, the screw terminal block can be used as an auxiliary power output.

Switch Inputs

The start sequence is triggered on the release (contacts opening) of the switch not the initial press.

There are two external inputs (CN2 / CN3) and an on-board switch S1.  Any of the these can be used to operate the unit; you choose which one depending on your specific requirements.  (see Board Connections section above)

The onboard switch and the two inputs are connected to the controller in a wired 'OR' configuration.  This means any or all switch/inputs can be used at the same time and the use of one does not preclude the use of the others. 

S1 Switch

The S1 switch on the PCB can be used for testing the board without any external switches connected. 

Non isolated switch input

The CN2 connector provides input for a non-isolated switch to be connected to the controller. 

Isolated switch input option

The isolated switch input needs its own power source to turn the LED on in the opto-isolator.   The 470R resistor supplied in the kit is suitable for voltages in the range 9-14 volts.

If you use a voltage outside this range you will need to substitute R6 with a different value resistor according to the voltage used in the external circuit. 

Suggested values for R6:

3 to 5  volts use 150R (5% 0.25 watt carbon film)
6 to 8  volts use 220R (5% 0.25 watt carbon film)
9 to 14 volts use 470R (2% 0.6 watt metal film - supplied with kit)
15 to 18 volts use 560R (2% 0.6 watt metal film)

for safety reasons do not use voltages > 18volts at this input

External start button

You can use any suitable push button switch with normally open (NO) contacts.  

The start button that can be seen in the photos on this page is available from Rapid Electronics part # 78-0182.  (also see part # 78-1550)

 

LED Clusters

The LED clusters are Kingbright type BL0307-50-44.  These contain 50 LED's connected as 10 parallel strings of 5 LEDs as shown in the schematic below.  The Kingbright LED clusters are available from a number of UK Suppliers

Maplin order code PD01B
Rapid order code 56-2985
RS stock No. 262-3015
Parts numbers correct at June 2009.
These parts may be available from other suppliers.

Download datasheet for Kingbright LED Cluster

Ensure they're connected to the controller with the red and white leads as shown in both the photos and indicated on the PCB overlay.  The  LED clusters illuminate sequentially from 1 to 5 and the connectors on the PCB overlay are numbered accordingly.

Adjusting Brightness

When JP1 is open, the controller drives the outputs using a PWM (pulse width modulated) signal.  This allows the brightness of the LEDs to be controlled by adjusting the position of PR1.  The PWM frequency is ~350Hz to avoid any visible flickering.   

The brightness control input is an analogue signal varying from 0 volts (dim) to 5 volts (bright).  For the technically minded it is possible to modify the circuit to use a Light Dependant Resistor or similar device to automatically adjust the LED brightness to match the ambient lighting.

JP2 Start Gate Timing Trigger

JP2 connector provides an open-collector output that can be used to trigger a timing control system, activate a light or buzzer.   The output is active at the end of the start sequence when the LEDs go out.  The duration of the output pulse is configurable (default 500mS)
If you need isolated dry contacts, use JP2 with an external CNY17 opto-isolator as shown.  Connect the output of the opto-isolator (pins 5,6) to the equipment being controlled.   

Two resistors are used to keep power dissipation below 0.25W in each resistor.

The actual output transistor is part of IC2 and it can sink up to 500mA.  Since it is part of IC2 there is an internal diode connected to the boards 12 volt supply.  This should be taken into account when making connection to an external circuit.  In particular ensure when the output transistor is off, the voltage at pin 3 does not exceed 12 volts otherwise the ULN2003A's internal diode will be forward biased and damage may occur.


Light Board Construction

The applications for the grid start controller project are varied and you will probably want to design your own housing for the complete assembly.

The drawing below is a suggested layout with dimensions for the construction of a board to mount the LED cluster modules and control PCB. 

The example below is constructed on 6mm MDF.  The LED Cluster modules have a neoprene sealing ring on the back of the module so with some thought the entire assembly could be made weather / rain proof.

PDF file version of drawing

For a two row board, you will need to duplicate the holes for the LED modules above the first row.  Don't duplicate the holes for mounting the control PCB.

Since the control PCB is mounted directly behind the middle LED module, it should be installed after the LED modules otherwise you can't get to the fixing bolt.

Photos below illustrate the assembly construction:



 
 

 


Output Drive Modes

If you have built the kit to work with the LED cluster modules you can skip this section.

The information here is useful if you plan on using the controller to operate relays or an alternative LED driver design.

The software supports three drive modes of which two are supported on the PCB.  The third mode may be used if you incorporate the microcontroller into your own hardware design.

The design of the circuit uses a single current limiting resistor (R1 & R2) for each row of LED clusters. For this to work only one LED cluster can be on at any time otherwise the more LEDs that turn on, the dimmer they get.  The software drives each output one at a time but it does so 350 times a second which makes them appear to the human eye to be on at the same time.  The reason it has been implemented this way is for two reasons.

  • The total maximum current required is that of 2 LED clusters rather than 10 so a smaller and cheaper power supply can be used.

  • The drive circuit uses a single ULN2003A transistor array and two resistors which keeps the cost down and the complexity of the circuit and PCB layout are simplified.

The output drive modes are jumper selectable.

Mode RA0 (JP1) RA4   Supported
 on PCB
Direct closed open  Use with relays and other devices that can't use PWM Y
Direct PWM * open closed (Gnd)  Use with LED driver that has individual current limiting N
Multiplexed PWM open open  Use with LED driver that has common current limiting Y

The RA0 / RA4 inputs have internal weak-pull enabled so there is no need for external pull up resistors. 

* On the PCB, RA0 is connected to JP1 but RA4 is not made directly available since the Direct PWM mode isn't supported by the hardware on the PCB.

Driving LED clusters with individual current limiting

The Direct PWM mode drives the outputs with a PWM signal which allows PR1 to adjust their brightness.  In this mode all the outputs are active simultaneously which requires individual current limiting for each LED module and a suitable output driver device that can handle the current/power dissipation.  This mode is enabled by connecting RA4 to ground.  Since this mode isn't support by the hardware on the PCB, there is no jumper on the PCB for it.  The functionality is provided if you want to incorporate the PIC microcontroller into a bespoke hardware design.

Driving Relays

If you need to drive lights or LED units that require more power, current or voltage than the controller board is designed for, you can interface the controller via relay driver boards.

A pictorial schematic for connecting relay driver boards is shown right.  Click on the link for PDF

  • Ensure JP1 is closed (either fit a jumper to the 2-pin header, or install a wire link).  If JP1 is not closed the relays will be driven with a PWM signal and won't operate correctly.
     
  • The Relays boards are made by Kitsrus.com and are available from distributors worldwide
    Datasheet: http://kitsrus.com/pdf/k156.pdf
    Please note Picprojects is not able to supply these relay boards

Custom control board

The photographs below are courtesy of Chris Hutchinson - Los Angeles Karting Championship

Chris used some 120 volt LED modules for the 'traffic light'.  As this only required 3 outputs driving a relay module the control board was supplied custom assembled without the components for the 12 volt LED modules.  Since only 3 channels were required custom timing parameters were used. By setting the delay on the first two channels to 0 it effectively makes it start from channel 3. The first two channels aren't used.

YouTube video clip


 

Firmware

The firmware for this project is only available in a pre-programmed PIC16F684 microcontroller. 

You can buy the PIC only, PIC and PCB or a complete kit of parts.  All these options are available to buy from the Picprojects online shop


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