I made a controller board for DIY projector.

Functionality:

-switch on / off the lamp with IR remote control
-drive 2 motor for keystone and focus (or DIY electric screen)
-protect overheat LCD panel
-read 3 temperatures (lamp / box / LCD panel) with high precision (0,5°C)
-drive 2 fan with RPM auto-ajustement


Here the schematic 1/2

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here the schematic 2/2 (go to http://forum.aspect-geek.net/index.php?showtopic=6224 for the complete project in my native language : French).

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Here Lamp temperature sensor

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Here LCD sensor, the box sensor is embedded on the controller board.

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here the controller board PCB with components

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here the devices side

here solder side

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Here PCB lamp sensor

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here LCD sensor

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here device side

An external sensor mesuring 2 X 2.1 cm

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here IR Remote control schematic

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The remote control mesuring 10,4 x 4,5 cm and work with 4 x AAA 1,5 V.

The remote control can learn some IR command from other existing remote control, 2 buttons can be assigned for this functionality...

here the solder side

Sorry I cannot continue caused by quota upload limitation on this forum per post, go to http://forum.aspect-geek.net/index.php?showtopic=6224 for complete project in my native language (sorry).

ummmm - i dont understand - WHY?
no offense, just not sure............

nice work tho!

Jeeeeze! Are you human or some sort of cyborg?!
Can you make us a cheap controller for laptop lcd's?
Haha, wouldnt that be nice.

Great work (I guess...)

Great work. Too bad you don't live next door to me.

Ricoks, I cannot upload anymore images. The posts in this forum have any quota limitations...

Great project!!

could you post a translation of the parts list and the pic program?

Thanks

Yes I can but I must translate too the LCD messages display in firmware...

I can send you the program now but not all functionality are implemented : it missing Fan RPM function, bootloader (for programming the PIC by a serial port from a PC) and IR remote RC5 (phillips IR protocole included in all universal remote).

I recently modified the board for reduce the cost (before I used MOS drivers) and for add the possibity to select between motor drive in 12V or 5V by ajusting an independent jumper for focus and keystone.

In the next day I will build the new board and I will finish the firmware for the first release version...

i think it is great project - all-in-one: IR, FAN, Keystone, Focus, Temperature + LCD info

wonderful

PS: use english words in PCB shema.. maybe someday i'll try to build the one.. (when using bulb), now it is not needed so much

Resistors
---------
1 R1 3.3k
1 R2 220
7 R3,R6,R7,R14,R16,R20,R22 1k
14 R4,R8,R10,R11,R13,R15,R17, 10k
R21,R23-R25,R27,R31,R32
1 R5 330
1 R9 150
3 R18,R19,R28 680
1 R26 39/1W
1 R29 390/1W
1 R30 4.7k

Capacitors
----------
3 C1,C14,C15 4u7
2 C2,C3 22p
2 C4,C10 330n
4 C5-C8 1u
3 C9,C11,C16 100n
2 C12,C13 220u

Integrated Circuits
-------------------
1 U1 PIC16F876
1 U2 7812
1 U3 7805
1 U4 MAX232
1 U5 MOC3041
1 U9 DS1621
1 U10 BTA16-600BW

Transistors
-----------
6 Q1,Q3,Q5,Q7,Q9,Q10 IRF530
4 Q2,Q4,Q6,Q8 IRF9530
1 Q11 2N2222
4 Q12-Q15 2N3904

Diodes
------
1 D1 Verte=green
5 D2,D6-D9 Rouge=red
2 D3,D10 Orange=orange !
2 D4,D5 1N4007
1 D11 1N4148
8 D12-D19 1N4001

Miscellaneous
-------------
1 ALIM EXT=external power suply 15 ~ 18 V
1 ALIM PC=direct 12V power supply input (if you have already an 12V power supply ex: PC ATX power supply)
1 BOUTON=buttons Used for reset timer and reset counter the number of switch on the lamp
1 BUTEES=Stop Switch used for stop Keystone and Focus motor if the mecanism arrive in end course
1 DIJONCTEUR Thermal protection a relay switch off 230V if excessive temperature and PIC Program are freezed

1 FUSIBLE=Fuse 5A T
1 HQI Alim HQI 230V = this on must be connected in serial with your lamp
1 IR TFMS5360 OU SFH506 = IR sensor
1 J1 CONN-D9F = DB9 female connector
1 J4 Moteur Focus = here connect your 5 or 12V focus motor
1 J5 Moteur Keystone = here connect your 5 or 12V focus keystone
1 J6 Tension Focus = jumper for selecting 5 or 12V power suply for focus motor
1 J7 Tension Keystone = jumper for selecting 5 or 12V power suply for focus motor
1 LCD AFFICHEUR 2X16 = Display LCD module 2X16 with backlight
1 P1 10K
1 P2 1K
1 RL1 G2RL-24-CF-DC12
1 SONDES Température = here connect external thermal sensor
1 VENT1 LCD = here connect LCD Fan
1 VENT2 HQI = here connect LCD Fan
1 X1 4Mhz

I dont know almost anything about diy electronic circuits, here is my list of simplified functions for a pj, perhaps someone more learned might help.

1- Delayed fan shutdown (5 minutes) after light goes out (to disipate residual heat)
2- Detection of fan death (alarm and light turn off)
3- Temp sensor (if too high, alarm and shut down)
4- Small lcd display with this info.

Regards

It is that do the zeltroleur controller board !!!

In fact the delayed time fan shutdown is determined by the temperature inside your box: If it's cold the delay will be short and reverse. The fan turn until temperature inside your box decrease until the programmed temperature. Theses programmed temperatures are stored in eeprom memory can be modified with the remote control by the user...

Doh, right
Im interested in the design, but I dont need it to drive any motors, dont want to use an rc and would like to control 3 or 4 fans, I still want an lcd display though.
I suppose this should simplify it a lot, can you help?

Plus, I´d like only 1 temp sensor (to make it even easier)

Very easy:
don't buy MOSFET, don't make extern sensor use 4 fan 2 per 2 in parallele and use 1 rpm wire per group. The alarm will be done only if the fan monitored in the group is defect. My controller check only 2 fans. Sorry.

zeltron, You should have been able to continue posting after 30 seconds wait. The restriction is to limit flooding and bot spammiing.

Cool stuff

You have very similar functions to the controller Im designing. I currently have version 1 embedded in my testbed projector. I didnt do keystone though because I wanted the controller to be generic, and keystone/focus correction is mechanically specific the the way the projector is built/etc.

Do you have a PIC of your controller embeded and working in a projector?

Do you have the code listing available? I mean... youve designed the card, posted the schematics, and the board artwork... so that must mean that you have debugged the system, lived with it for a while in a real projector, and are ready to move to full scale production correct?

Or our you pulling our leg?

Schematics and board artwork dont impress me... I want to see it embedded and working. Anyone can make a Schematic and board artwork.

Cool ! Have you some pics of your controller ? What is the microcontroller have you used ?

The keystone or focus function can be used for drive an electric screen also !!!

I want also make a generic controlleur, so if you don't need focus and keystone or drive an electric screen : don't buy MOSFETs !!!

I made this controller because I never seen on internet a modern DIY projector, so I would like to try with this have equal functionnality with commercial projector have.




Yes of course, and I don't want impress anyone !!! (strange remark). I paused my post because I cannot upload any images (thanks brainchild for you explaination).

I attached a PIC with this answer , So I retry to post....

[edit]: unsuccessfull (sorry brainchild it is not the limit flooding and bot spamming protection) I have this message:

"THE FOLLOWING ERROR(S) WERE FOUND
The total filespace required to upload all the attached files is greater than your per post or global limit. Please reduce the number of attachments or the size of the attachments."

Can I make another topic ?

The file size of your image is too big. You will need to make the file size smaller.

Well aren't you special.

That is kind of harsh when someone is trying to share their ideas. He has obviously put alot of time into this. Are you jealous maybe?

Geez... I was just kidding with the guy... lighten up.



I used a PIC16F876 for the 1st version... The next one Im planning on moving up to the PIC16F877 for more IO pins. Even with upgrading the pic though I think that Im going to have to use more than one controller on this design. At least do a serial LCD interface instead of going the parallel route to conserve IO pins. Ive been running version 1 for the past several weeks in my testbed projector. Its definitely alot more comforting having a truly intelligently controlled projector over the old mechanical switch method.

Just curious... Are you posting the artwork and schematics so that someone could actually build this?

I just finish it, so nobody else than me have build it at this moment. I prefer add a bootloader functionnaly by PC serial port for anybody can upgrade the firmware easly before release it.

The controller board is fully working I removed all previous schematic for add this attached picture...



No BoomerBrian, the file size less 90kb and the resolution is 640x480, I think the forum have a limitation for total attached files by post. I trying reduce or remove previous posted schematics for have more ko available for continued my post. It is very convenient...

I have enough space for add this one...

Clap-Clap

That is pretty awesome zeltron.


Hmmm. If that is the case zeltron I don't know. A moderator should be able to help.




Luca, I read it as if you were taking a shot at zeltron. That is one problem with forums. It is hard sometimes to tell the tone since everything is typed. If you were kidding then no harm done. I apologize.

Im digging it.

What PC Board Design software are you using? Ive been using PCB123... seems to work pretty well. For the version 1 prototype of the controller I designed, I just manually wired up a board using point to point soldering because I figured it was the quickest way for me to get something up and running, and would be easier/less expensive to change until I had all the version 1 features in place.



(not that Im Australian but...)

No worries mate!

I guess my dry New Yorker style of humor doesnt always translate well into typed media.

I used proteus with custom library made by myself, but any other electronic CAD software can be used, When you show the schematic (sorry deleted) you can alway reconize an electronic CAD software because only few populars are alway used.

Oh...

zeltron...

I almost forgot.

here is the link to the thread where I started designing/building the p-brain Version 1. You havent seen this yet?

http://www.diyaudio.com/forums/showthread....&threadid=62055

It goes through the initial thought to actually embedding the controller into a projector. Im surprised that you have never seen this thread.

Ive been running it for the past several weeks... Its SO sweet!

Good luck chief.

Sorry I am a new member for projector DIY , I never seen this post before but on diyaudio.com forum the topics are not very good classed ...

I am registred in diyaudio.com but I am still under moderation...

Your project is also great ! Have you better picture of your controller board because on your topic we can see solder side only...

Unfortunately I dont... my Camera is really poor anyway, as you could probably tell from the blurry photos.

Its currently embedded in the projector though... Ive had to do a few software bug fixes/upgrades since I installed it. Ive been using an ISP-PRO PIC programmer to upgrade the firmware, I havent installed a bootloader yet.

Do you have a projector ready that you plan to embed this into?

Yes I have it but I wait my lumenlab pro lens 500mm for finish it with electric focus system...

How long have you been doing PCB design?

Im definitely a newbie at it. I have 20 years of Software Development/System Architecture/Coding experience, but the whole PCB design thing is new to me.

Ive been playing around with PCB123, and it seems like its pretty good (especially since its free). I like the fact that the board ordering process is built right into the PCB layout software, so that when you make a change to a board it shows you the change in unit price/etc. I found though, like you, that I ended up having to create my own component and package libraries. Right now Im working on building a library of Digikey screw type PCB Terminal Blocks... man...it takes alot of time to get this stuff defined.

Oh Well.

I designed the schematic, proteus auto-generate PCB from schematic. I organized the place and manually route wire. So I think the complete design take me 10 hours around...

If you modifie schematic, the PCB is syncronised but you must before delete old routed wire manually for little modifications or run again a complete auto-route for the large modifications.

Unfortually Proteus is not free, the eval version cannot save...

By any chance does anyone have the PCB123 save file for this? Or do they know how much this would cost to build? Is there any chance of an english version of the firmware? And what are the odds of this being made into a kit? Sorry for all the questions. I am just in the initial stages of planning my new pro lens projector.


Thanks

Brad

the links on the first page of this thread don't seem to be working.

you're allright our french forum have moved recently to : http://forum.aspect-geek.net/aspectgeek/El...ujet-6224-1.htm

The release version will be available of course in french and english, I wil wrote a english file for other language translations.

Actually I finish PWM timing, after that I will be write the bootloader for all firmware can be upgraded by the user with his PC by serial port.

Be patient !