Continuous Liquid Level Controller

GROUP ID: 14 Continuous Liquid Level Controller
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1. INTRODUCTION
In Continuous Liquid Level Controller, Pump will play the role of a door which will be
opened and closed as per the real time situation. Sensors are interfaced with the Micro-
controller and equipped with the most reliable logical operations so that the most précised
leveling of the tank is known to the user on the LCD screen. The output of the sensor will
control the operation of the pump/buzzer. Hence our Minor Model will be equipped with the
Smart Sensors eligible to contribute its best possible outcome to the Micro-controller. At
maximum and threshold level of the tank a buzzer will be heard which will take care of the
human values and thereby will take a step towards creating a user-friendly as well as eco-
friendly environment.
A complete logic is loaded in the controller so that it follows the instruction of the
programmer appropriately and works accordingly. The aim of building this model is to save
liquid resources and enhance human life in all contexts. This prototype is a reference to the
industrial application where continuous liquid control and its monitoring is essential. Hence
this model shows our sincere effort in building the Continuous Liquid Level Controller
(CLLC) which is a step towards the welfare of the society using embedded technologies.

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2. LITERATURE WORK
As a part of basic literature survey, we have the PSAR report, in which we studied
description about following topics:
 Improvements in or relating to liquid level indicator
 Magnetic liquid level indicator
 Liquid Level Indicator using Laser beam
 Continuous level indicator for solids and liquids.
 Non-contact type water level control apparatus.
 High-Low level alarm controller
 Noninvasive Ultrasonic liquid Level Indicator
 Water level detector and indicator system
 liquid level indicator using lights
 Liquid level monitoring and reporting system
* Detailed description about the topics are mentioned in PSAR report
Besides that we have gone through few website, which helps us to get information about our
topics, which are mentioned in bibliography.

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3. Materials, Software and methods used
3.1 Hardware Components:
 Microcontroller – ATMEGA-16A (AVR)
 LCD 16 x 2 - JHD 16*2
 ULN2003AC - (Qty. 1)
 Regulator IC – LM7805
 Relay - JQC-3FC (T73) DC 12V
 Buzzer
 Voltage Regulator - LM7805
 Submersible Pump
 Sensor – Ultrasonic Distance Sensor
 Electrolytic Capacitor
3.1.1) ATMEGA16 (AVR) CONTROLLER

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3.1.1.1) General Description
Atmega16 is a low power CMOS 8bit microcontroller based on AVR enhances RISC
architecture. By executing powerful instructions in a single clock the atmega16 achieves
throughput approaching 1MIPS per MHZ allowing the system designer to optimize power
consumption versus processing speed. The main function of ATmega16 is to ensure correct
program execution. The CPU must therefore be able to access memories, perform
calculations, control peripherals and handle interrupts.
3.1.1.2) Features
 High-performance, Low-power AVR® 8-bit Microcontroller
 Advanced RISC Architecture
 131 Powerful Instructions 131 Powerful Instructions
 Most Single Most Single--clock Cycle Execution clock Cycle Execution
 32 x 8 General Purpose Working Registers
 Fully Static Operation
 Up to 16 MIPS Throughput at 16 MHz
 On-chip 2-cycle Multiplier
 High Endurance Non-volatile Memory segments
 16K Bytes of In-System Self-programmable Flash program memory
 512 Bytes EEPROM
 1K Byte Internal SRAM
 Write/Erase Cycles: 10,000 Flash/100,000 EEPROM
 Optional Boot Code Section with Independent Lock Bits
 In-System Programming by On-chip Boot Program
 True Read-While-Write Operation
 Programming Lock for Software Security

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3.1.1.3) PIN DESCRIPTION
VCC: Digital supply voltage.
GND: Ground.
Port A (PA7..PA0): Port A serves as the analog inputs to the A/D Converter.Port A
also serves as an 8-bit bi-directional I/O port, if the A/D Converter is not used. Port pins can
provide internal pull-up resistors (selected for each bit). The Port A output buffers have sym-
metrical drive characteristics with both high sink and source capability. When pins PA0 to
PA7 are used as inputs and are externally pulled low, they will source current if the internal
pull-up resistors are activated . The Port A pins are tri-stated when a reset condition becomes
active, even if the clock is not running.
Port B (PB7..PB0): Port B is an 8-bit bi-directional I/O port with internal pull-up
resistors (selected for each bit). The Port B output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port B pins that are
externally pulled low will source current if the pull-up resistors are activated. The Port B pins
are tri-stated when a reset condition becomes active, even if the clock is not running.
Port B also serves the functions of various special features of the ATmega16 as listed on page
58.
Port C (PC7..PC0): Port C is an 8-bit bi-directional I/O port with internal pull-up
resistors (selected for each bit). The Port C output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port C pins that are
externally pulled low will source current if the pull-up resistors are activated. The Port C pins
are tri-stated when a reset condition becomes active, even if the clock is not running. If the
JTAG interface is enabled, the pull-up resistors on pins PC5(TDI), PC3(TMS) and
PC2(TCK) will be activated even if a reset occurs.
Port C also serves the functions of the JTAG interface and other special features of the
ATmega16 as listed on page 61.

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Port D (PD7..PD0): Port D is an 8-bit bi-directional I/O port with internal pull-up
resistors (selected for each bit). The Port D output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port D pins that are
externally pulled low will source current if the pull-up resistors are activated. The Port D pins
are tri-stated when a reset condition becomes active, even if the clock is not running.
Port D also serves the functions of various special features of the ATmega16 as listed on page
63.
RESET: Reset Input. A low level on this pin for longer than the minimum
pulse length will generate a reset, even if the clock is not running. The minimum pulse length
is given in Table 15 on page 38. Shorter pulses are not guaranteed to generate a reset.
XTAL1: Input to the inverting Oscillator amplifier and input to the internal
clock operating circuit.
XTAL2: Output from the inverting Oscillator amplifier.
AVCC: AVCC is the supply voltage pin for Port A and the A/D Converter.
It should be externally connected to VCC, even if the ADC is not used. If the ADC is used,
it should be connected to VCC through a low-pass filter.
AREF: AREF is the analog reference pin for the A/D Converter.
3.1.1.4) ADVANTAGES
 Small instruction set to learn
 RISC architecture
 Built in oscillator with selectable speeds
 Inexpensive
 Wide range of interfaces including I²C, SPI, USB, USART, A/D, programmable
comparators, PWM, LIN, CAN, PSP, and Ethernet.
 Availability of processors in DIL package make them easy to handle for hobby use.

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3.1.1.5) LIMITATIONS
 One accumulator
 Register-bank switching is required to access the entire RAM of many devices
 Operations and registers are not orthogonal; some instructions can address RAM
and/or immediate constants, while others can only use the accumulator.
3.1.2) ULN 2003 AMPLIFIER
3.1.2.1) GENERAL DESCRIPTION
ULN2003 is a high voltage and high current Darlington array IC. It contains seven open
collector Darlington pairs with common emitters. A Darlington pair is an arrangement of two
bipolar transistors.
ULN2003 belongs to the family of ULN200X series of ICs. Different versions of this family
interface to different logic families. ULN2003 is for 5V TTL, CMOS logic devices. These
ICs are used when driving a wide range of loads and are used as relay drivers, display drivers,
line drivers etc. ULN2003 is also commonly used while driving Stepper Motors.
The ULN2003 is a monolithic IC consists of seven NPN Darlington transistor pairs with high
voltage and current capability. It is commonly used for applications such as relay drivers,
motor, display drivers, led lamp drivers, logic buffers, line drivers, hammer drivers and other

VIER (EC) - 8 -
high voltage current applications. It consists of common cathode clamp diodes for each NPN
Darlington pair which makes this driver IC useful for switching inductive loads.
The output of the driver is open collector and the collector current rating of each Darlington
pair is 500mA. Darlington pairs may be paralleled if higher current is required. The driver IC
also consists of a 2.7KΩ base resistor for each Darlington pair. Thus each Darlington pair can
be operated directly with TTL or 5V CMOS devices. This driver IC can be used for high
voltage applications up to 50V.

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3.1.2.2.) Pin Description:
Pin No Function Name
1 Input for 1st
channel Input 1
2 Input for 2nd
channel Input 2
3 Input for 3rd
channel Input 3
4 Input for 4th
channel Input 4
5 Input for 5th
channel Input 5
6 Input for 6th
channel Input 6
7 Input for 7th
channel Input 7
8 Ground (0V) Ground
9 Common freewheeling diodes Common
10 Output for 7th
channel Output 7
11 Output for 6th
channel Output 6
12 Output for 5th
channel Output 5
13 Output for 4th
channel Output 4
14 Output for 3rd
channel Output 3
15 Output for 2nd
channel Output 2
16 Output for 1st
channel Output 1

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3.1.3) 7805 REGULATOR IC
Positive Voltage Regulator ICs
The L78xx series of three-terminal positive regulators is available in TO-220, TO-220FP,
TO-3, D²PAK and DPAK packages and several fixed output voltages, making it useful in a
wide range of applications.
These regulators can provide local on-card regulation, eliminating the distribution problems
associated with single point regulation. Each type employs internal current limiting, thermal
shut-down and safe area protection, making it essentially indestructible. If adequate heat
sinking is provided, they can deliver over 1 A output current. Although designed primarily as
fixed voltage regulators, these devices can be used with external components to obtain
adjustable voltage and currents.
3.1.3.2) FEATURES
 Output current up to 1.5 A
 Output voltages of 5; 6; 8; 8.5; 9; 12; 15; 18; 24 V
 Thermal overload protection
 Short circuit protection
 Output transition SOA protection
 2 % output voltage tolerance
 Guaranteed in extended temperature range

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3.1.4) BUZZER
Piezo buzzer is an electronic device commonly used to produce sound. Light weight, simple
construction and low price make it usable in various applications like car/truck reversing
indicator, computers, call bells etc. Piezo buzzer is based on the inverse principle of piezo
electricity discovered in 1880 by Jacques and Pierre Curie. It is the phenomena of generating
electricity when mechanical pressure is applied to certain materials and the vice versa is also
true. Such materials are called piezo electric materials. Piezo electric materials are either
naturally available or manmade. Piezoceramic is class of manmade material, which poses
piezo electric effect and is widely used to make disc, the heart of piezo buzzer. When
subjected to an alternating electric field they stretch or compress, in accordance with the
frequency of the signal thereby producing sound.

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3.1.5) Submersible pump
A water pump with an electric motor in the same housing with the pump, designed to operate
while submerged in water. Eliminates suction lift limitations, loss of prime, need for suction
hose, and the noise and fumes of an internal combustion engine.
A submersible water pump operates beneath the earth's surface. A submersible water pump
will not operate if it is not submerged in liquid. A submersible water pump pushes water to
the surface, instead of sucking the water out of the ground like above ground water pumps.
Most submersible pumps are long cylinders that are about 3 to 5 inches around and 2 to 4 feet
long. Submersible water pumps have a hermetically sealed motor that is close-coupled to the
body of the water pump. Having a hermetically sealed motor prevents the water from getting
inside the pumps motor and causing a short circuit. Other components of a submersible water
pump are the cable, which is connected to the motor, and a pipe that transports the water to
the surface of the well.

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3.1.6) ULTRASONIC SENSOR
3.1.6.1) Features
Minimum range 10 centimeters
• Maximum range 400 centimeters (4 Meters)
• Accuracy of +-1 cm
• Resolution 1 cm
• 5V DC Supply voltage
• Compact sized SMD design
• Modulated at 40 kHz
• Serial data of 9600 bps TTL level output for easy interface with any microcontroller.

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3.1.7) DC RELAY 12 V
Relay is an electromagnetic device which is used to isolate two circuits electrically and
connect them magnetically. They are very useful devices and allow one circuit to switch
another one while they are completely separate. They are often used to interface an electronic
circuit (working at a low voltage) to an electrical circuit which works at very high voltage.
For example, a relay can make a 5V DC battery circuit to switch a 230V AC mains circuit.
Thus a small sensor circuit can drive, say, a fan or an electric bulb.
A relay switch can be divided into two parts: input and output. The input section has a coil
which generates magnetic field when a small voltage from an electronic circuit is applied to
it. This voltage is called the operating voltage. Commonly used relays are available in
different configuration of operating voltages like 6V, 9V, 12V, 24V etc. The output section
consists of contactors which connect or disconnect mechanically. In a basic relay there are
three contactors: normally open (NO), normally closed (NC) and common (COM). At no
input state, the COM is connected to NC. When the operating voltage is applied the relay coil
gets energized and the COM changes contact to NO. Different relay configurations are
available like SPST, SPDT, DPDT etc, which have different number of changeover contacts.
By using proper combination of contactors, the electrical circuit can be switched on and off.

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3.1.8) POLARIZED CAPACITOR
A polarized capacitor is one which has a polarity, positive on one terminal, negative on the
other. This makes it superficially look like a battery. In use, the capacitor has its positive
voltage always higher than that on the negative terminal, it matters that this is the case and
this gives rise to the term polarized. This sort of capacitor is commonly found in power
supply filters.
3.1.8.2) SYMBOL OF POLARIZED CAPACITOR;

VIER (EC) - 16 -
3.1.8.3) Polarized fixed capacitor
A polarized ("polar") capacitor is a type of capacitor that have implicit polarity -- it can only
be connected one way in a circuit. The positive lead is shown on the schematic (and often on
the capacitor) with a little "+" symbol. The negative lead is generally not shown on the
schematic, but may be marked on the capacitor with a bar or "-" symbol. Polarized capacitors
are generally electrolytic.
One really needs to pay attention to correctly hooking a polarized capacitor up (both with
respect to polarity, as well as not pushing a capacitor past its rated voltage). If one pushes a
polarized capacitor hard enough, it is possible to begin "electrolyzing" the moist electrolyte.
Modern electrolytic capacitors usually have a pressure relief vent to prevent catastrophic
failure of the aluminum can.
Just remember that polarized capacitors usually have large capacitance per volume compared
to non-polar caps (like ceramic). So it might be hard to find a non-polar cap with an
equivalent value as long as the voltage and capacitance matches.
-

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3.1.9) LCD DISPLAY
This is 2 lines by 16 characters LCD display, HD44780-compatible controller, with a
yellow/green backlight. Note: The documentation link is to a slightly different type, but the
connections are the same. The backlight does not have separate pins, it connects to the
ground and 5 Volt pin, the series resistor is in the LCD.
LCD (Liquid Crystal Display) screen is an electronic display module and find a wide range of
applications. A 16x2 LCD display is very basic module and is very commonly used in
various devices and circuits. These modules are preferred over seven segments and other
multi segment LEDs. The reasons being: LCDs are economical; easily programmable; have
no limitation of displaying special & even custom characters (unlike in seven segments),
animations and so on.

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3.1.9.2) Pin Description:
Pin
No
Function Name
1 Ground (0V) Ground
2 Supply voltage; 5V (4.7V – 5.3V) Vcc
3 Contrast adjustment; through a variable resistor VEE
4 Selects command register when low; and data register when high Register Select
5 Low to write to the register; High to read from the register Read/write
6 Sends data to data pins when a high to low pulse is given Enable
7
8-bit data pins
DB0
8 DB1
9 DB2
10 DB3
11 DB4
12 DB5
13 DB6
14 DB7
15 Backlight VCC (5V) Led+
16 Backlight Ground (0V) Led-

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3.2 METHODS:
 There were lots of ways to sense the level of liquid i.e. one can calculate the continuous
level of liquid or it may be discrete in nature.
 As we were interested in measuring the continuous level, we worked on the same.
 There are many sensors from which one can do the need, but we found Ultrasonic
distance sensor to be more efficient .
3.2.1) BLOCK DIAGRAM

VIER (EC) - 20 -
3.2.2) Description
 The above diagram gives the pictorial representation of the devices interfaced with the
microcontroller.
 Modules included in the block diagram are:
1) Power supply
2) Microcontroller (CPU)
3) Primary and Secondary tank.
4) Output Devices.
5) Input Devices.
3.2.2.1) Power supply module :
A power supply is a device that supplies electric power to microcontroller and various
other modules which need 5V OR 12V power respectively. A regulated power
supply is one that controls the output voltage or current to a specific value; the
controlled value is held nearly constant despite variations in either load current or the
voltage supplied by the power supply's energy source.
3.2.2.2) Microcontroller (CPU):
A Processing unit which processes data coming from the input devices with the help
of arithmetic and logical operations and responds to the output devices appropriately
is called as Microcontroller.
3.2.2.3) Primary and Secondary tank :
Our model uses two tanks namely primary tank in which sensor resides and secondary
tank in which pump resides. Both these tank can communicate with each other using
an embedded program built into the Microcontroller through an appropriate circuit
design.
3.2.2.4) Output Devices:
The project includes various output devices such as Pump, LCD and Buzzer.
These output devices are activated as per the real time situation and their duty cycle is
determined by the processing unit (Atmega16).

VIER (EC) - 21 -
3.2.2.5) Input Devices:
This minor model encompasses a sensor as an input device that controls the entire
functioning of the project by transmitting and receiving sound waves thereby using an
Acoustic method for leveling the primary tank taking into account the status the
secondary tank.

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3.3 SOFTWARES:
 Two software were used to design & program our project, one for each i.e.,
Proteus 8 : for design & simulation &
MikroC Pro for AVR : for programming
3.3.1) SIMULATION SOFTWARE
Proteus 8 is a single application with many service modules offering different functionality
(schematic capture, PCB layout, etc.). The wrapper that enables all of the various tools to
communicate with each other consists of three main parts.
Application Framework
Proteus 8 consists of a single application (PDS.EXE). This is the framework or container
which hosts all of the functionality of Proteus. ISIS, ARES, 3DV all open as tabbed windows
within this framework and therefore all have access to the common database.
Common Database
The common database contains information about parts used in the project. A part can
contain both a schematic component and a PCB footprint as well both user and system
properties. Shared access to this database by all application modules makes possible a huge
number of new features, many of which will evolve over the course of the Version 8
lifecycle.
Live Netlist
Together with the common database the maintenance of a live netlist allows all open modules
to automatically reflect changes. The most obvious example of this is wiring in ISIS
producing ratsnest connections in ARES but it goes much further than that. The new Bill of
Materials module contains a live viewer and the 3D Viewer and Design Explorer are also
linked into the live netlist.

VIER (EC) - 23 -
Snapshot of software:

VIER (EC) - 24 -
3.3.3.1) Circuit design of the project

VIER (EC) - 25 -
3.3.2) PROGRAMMING SOFTWARE
3.3.2.1) MikroC Pro for AVR
 It is easy to create embedded programs on AVR series through this software.
 It allows project management, source code editing, program debugging and complete
simulation in one powerful environment.
 More user friendly then C-Programming.
 The mikroC PRO for AVR is a powerful, feature-rich development tool for AVR
microcontrollers.
 It is designed to provide the programmer with the easiest possible solution to
developing application for embedded systems, without compromising performance or
control.
 It allows quickly to develop and deploy complex applications.
Snapshots

VIER (EC) - 26 -

VIER (EC) - 27 -
4. PROJECT PROGRAM
C- PROGRAM
sbit LCD_RS at PORTc5_bit;
sbit LCD_EN at PORTc4_bit;
sbit LCD_D4 at PORTc3_bit;
sbit relay at PORTa5_bit;
sbit relay1 at PORTa2_bit;
sbit LCD_RS_Direction at DDc5_bit;
sbit LCD_EN_Direction at DDc4_bit;
sbit LCD_D4_Direction at DDc3_bit;
sbit LCD_D7_Direction at DDc0_bit; // End LCD module
connections
char i,j,k,l,m,n,o,p;
char r;
int A=0 ;
char txt[6];
void main(){
Lcd_Init(); // Initialize LCD
Lcd_Cmd(_LCD_CLEAR); // Clear display
Lcd_Cmd(_LCD_CURSOR_OFF); // Cursor off
Lcd_Out(1,1,"Continuous Level Indicator"); // Write text in first row
Delay_ms(250);
DDRA = 0xff; // As OP
relay=1;
relay1=1;
UART1_Init(9600); // Initialize UART module at 9600 bps
Delay_ms(100); // Wait for UART module to stabilize
h1:
while (1)
{

VIER (EC) - 28 -
if (UART1_Data_Ready()) { // If data is received,
p = UART1_Read(); // read the received data,
/* Lcd_chr(2,1,p); */
goto x1;
}
}
x1:
while (1)
{
i = UART1_Read(); // read the received data,
Lcd_chr(2,1,i);
goto x2;
}
}
x2:
while (1)
{
j = UART1_Read(); // read the received data,
Lcd_chr(2,2,j);
goto x3;
}
}
x3:
while (1)
{
k = UART1_Read(); // read the received data,
Lcd_chr(2,3,k);
goto x4;
}
}
x4:
while (1)
{

VIER (EC) - 29 -
l = UART1_Read(); // read the received data,
Lcd_chr(2,4,l);
goto x5;
}
}
x5:
while (1)
{
m = UART1_Read(); // read the received data,
Lcd_chr(2,5,m);
goto x6;
}
}
x6:
while (1)
{
n = UART1_Read(); // read the received data,
if(n== 0x63) //63- ASCII value of 'c'
{
Lcd_chr(2,6,n);
goto x7; }
goto x6;
}
}
x7:
while (1)
{
x10:
o = UART1_Read(); // read the received data,
if(o== 0x6D) // 6D-ASCII value of 'm'
{
Lcd_chr(2,7,o); // conversion from ASCII to Decimal

VIER (EC) - 30 -
i= i-0x30 ;
i = i*100;
j= j-0x30 ;
j= j*10;
k= k-0x30 ;
k = k*1;
A = i+j+k;
WordToStr(A, txt);
Lcd_out(2,10,txt);
if (a <25 || a>50 )
{
Lcd_out(1,1,"BUZZER ON ");
relAY1 = 0;
delay_ms(50);
}
else
{
Lcd_out(1,1,"BUZZER OFF ");
relAY1 = 1;
delay_ms(50);
}
goto h1;
}
goto x10;
}
}
}

VIER (EC) - 31 -
5. TESTING AND VERIFICATION

VIER (EC) - 32 -
6. ADVANTAGES & APPLICATIONS
6.1) ADVANTAGES
 We will Conserve three IMPORTANT resources: LIQUID, POWER, and TIME.
LIQUID- Ensures uninterrupted water supply, never allows tank to spill over or lie
empty.
POWER - Low power consumption leads to power conservation.
TIME – Use of MICROCONTROLLER as logic circuitry automates the whole
process which
 ultimately saves the time of user.
 No use of power circuitry at the sensing level while using .
 VERSATILITY- Usable with tank of any size.
 Reduces man power.
 Work efficiently.
 Power saving.
 Work with ease.
 User Friendly.
6.2) APPLICATIONS
 Our minor model has a very wider scope in the field of chemical and pharmaceutical
industries where continuous level of the tank is required for 24 hour monitoring the
status of the resource.
 Moreover the project can have its effect in the field of mechanical engineering in the
form of Boiler Monitoring.
 Automated water level indicator can be extensively used to check the increasing and
decreasing level of water in the tank and pipes in various establishments such as
factories, hotels, restaurants, hospitals, offices, schools, colleges and multi-storey
residential apartments having over head water tank of any size, shape and model. So,
no need to go on the roof to check the water level.
 Can be used for Municipal water taps for indication of flow of water from tap.
 Can also be used to measure underground storage of water.

VIER (EC) - 33 -
 Can be used to predict the arrival of floods.
 Water level indicators are used to monitor water level in standpipes and wells.
 Used widely in hydraulic industries.

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7. FUTURE SCOPE and CONCLUSION
7.1) FUTURE SCOPE
 Any kind of modification as per the need can be done.
 Vast scope in Bottle filling system.
 With the use of color sensors type of liquid can be detected.
Flow sensors can be used in future to measure the amount of liquid flowing through
the Valves of the tank in the industries.
7.2) CONCLUSION
 The main purpose behind this project was to learn about the various functions of
Atmega16 Controller. We learnt how the real time application works by
communicating various electronic devices by studying their construction and
functions thereby achieving the desired values as per the requirement. We also
learned about how various output devices are interfaced with Atmega16 controller.
With great eagerness we carefully programmed each device which was indeed a very
interesting job done during the term. Finally on completion of this project, our ability
as an engineer is boosted up and now we are sure for our bright future.

VIER (EC) - 35 -
Bibliography
 www.sunromtechnologies.com
 www.robokits.com
 www.youtube.com
 www.engineeringprojects.com
 www.engineersgarage.com
 www.wikipedia.com
 www.alldatasheet.com
 www.slideshare.com

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