Essen Electronics

 Many Industrial devices need li-ion battery packs for their backup power. after long use the battery pack may get old and should replaced with new battery pack. some times ready made battery pack not available in the market. so we can make one using proper li -ion batteries with BMS circuits.  These battery pack i made using spot welding machine in previous post

 Spot welding Machine is an important device for making li ion Battery packs. so I decided to make one. I got a old Transformer from a Micro wave Oven. and remove its secondary windings by cutting the copper wire. and make a high Ampere Low Voltage secondary by 2 Turns of Thick copper wire .and connect the terminals with 2 thick Copper nail. Make one timer circuit and connect the primary of that transformer with that.  now the welding unit is ready we can make spot welding to batteries with tin connector by pressing the nail with the welding spot and  a push a switch. the timer give power to the transformer for 1 second and the spot get welded well    

 This is an ON /OFF electronic switch for a Light. that can be controlled from any number of switches at multiple location. each press of any switch toggle the light ON or OFF.

I make this device for testing All SCR's , MOSFET.and LED's

 I make this circuit for school buses. when the bus driver put the ignition key and start the bus. this device get ready and waiting for removal of key. when the driver halt and remove the key in the destination, the alarm fixed in the rear side of the bus start loud  beeping. so the driver must go to the rear side of the bus and silence the alarm by pressing a push switch once, and while he return he can check the seats for any sleeping kids. the alarm itself  notify to the kids that that there destination is reached. the driver cannot skip this routine.  once the alarm is silenced the device will off and it will get ready  at the next start.  

 This circuit board contain 12 Soft switches. when once pressed the relevant LED ON and  it will OFF at next press. there is on more switch is there used for switch on All LED's on one press.  You can also use relays with its out output to control any electrical device

 This circuit is actually a light detector. when light falls on the LDR  it trigger an alarm sound. its a school project .this circuit attached with a model remote car .every time the car passes under a model tunnel it make alarm.

 This small device can detect hidden  live main wire without touching the cable. mainly used to find cable hidden beneath the wall. And also we can use this to detecting the invisible broken  point of a long power cable.  a LED Lamp glow when it brought near a live wire.  IT uses a button cell for the power and an ON OFF switch is used to save the battery when it is not in use. Updated with push sw instead of ON OFF switch                  

 while working on Power supply boards we need to discharge  the main High voltage Capacitor.There may be current charge up to 400 v DC . such capacitor are   very dangerous to touch with bare hands. Discharge it by shorting terminals may damage the PCB itself So I made this simple tool. by using this we can  safely discharge the voltage in big capacitors. even we can know the polarity of capacitor. once we connect an LED start Glowing and goes off when the capacitor discharge completely. the green LED lights indicate right polarity .and the Red LED indicate the Polarity reversed. in any polarity it discharge the capacitor.

  This is an window comparator circuit.  When the input voltage level reach 0 to 2.7 v the relay get on and when it reach 3v it goes off. It will sense the precise voltage level.  My customer want this circuit with this specification for controlling some gas valve.

  I make this circuit for display box in a electronics showroom. 4 way stereo selector switch. when we soft press any switch,the mp3 player output is routed to selected set of speaker ,this will help customer to compare quality up to 4 speaker. digital switch used instead off mechanical relay,when we press the switch it latches and play to one output until another select.

  I design this simple circuit use a cheap 15 aed phone. it can on / wait/ off a light or any electrical device by a missed call . switch on/off any thing in your home while you are away. By just call the dedicated number.. the circuit get power from the phone itself.

  This simple ic Tester i made to test most of the 8 pin PWM IC's used SMPS power supply circuits. Just insert the suspected ic in the socket .If he LED is on and can change the brightnes when turn the preset..then it is good. Otherwise ic is faulty . its handy and save time .

  Today i made this Test instrument using Arduino ..very very usefull in find out shorted electronic components in mainboards.. espcially when lot of ICs sharing same power. if one componet get short the whole track shows 0 resistance when testing with normal multimeter.. its difficult to find which one is the dead rat.  Normally we need to take out each suspected component from board and need to test until we got the defective one.. its tedious job and damage the board.    Another way inject current to the circuit test the heat.. its not safe.   Here is the need of this device. When we trace the power line with this probe.. it gives high pitch audio tone when the probe near the particular shorted component.. It can test micro ohm resistance beyond normal meter range Automatically shut to save battery .if we forget to switch of the tester Auto calibration range. Portable The tester voltage and current safe to testing any components . On board testable...

working in 24 V DC using Buck converter for high efficiency  Used 2-16 blue /white LCD Display with back light micro controller based circuit. 4 relays (24V /10A each)used for Output control . microcontroller outputs are opto isolated from relays for additional protection sensors for temperature /pressure are 4-20 mA (1-5V) range type Can be set desired Temperature /Pressure using UP DOWN Black push buttons in the set mode then press the Green OK button the device goes to monitor mode. The displayed control range is 0 -100 for 4-20 mA input. when the temperature /pressure goes below the preset value then 24 volt available at appropriate output this can used to switch a contactor on ,hence a heater or compressor can be switch on. when the temperature /pressure reach 5 point less than the preset value,24 volt available at its alarm out put to drive a buzzer and it only off when the temperature and pressure goes10 point below the preset value when the temperature or pressure reach the...

 Once I need to connect an EDC flash disk to pc and want to check  the files. I cannot find a right adapter for EDC disks. so I make a connector with two 40 pin socket and connect the right pins . and bought one normal hard disk to USB adapter and connect the adapter in one side. and other side connect the EDC flash disk .just i connect power tho the EDC disl and connect the USB cable of adapter to the PC. Now the PC detect the disk and I can see edit all files inside the EDC disk

This simple circuit is Door watch alarm i made for a video game center.  When customer open a door this alarm wait for a preset time (may 30 minutes). The time cane bet set by adjusting pot. even after this time if the door still open this will  make an alarm ..or close the door or activate any thing by relay switch .

 Once this switch is ON the light or any Load will ON and wait for some Time . That waiting time we can adjust by setting the Variable Resistor.   after the pre setted time this device will switch OFF the load. this  can be used in staircase. toilet, garage or even in car interior light. and in such places where we frequently forget  to switch off. this time delay can be variable in seconds or minutes.

  This project is a 2 Digit Counter. uses arduino and 2 seven segment LED displays we can set desired number of counts first. and each pressing of a count button the number showing in the display start counting down  instead of count button we can use any sensor to count "n" number of incidents, when it reach 0 a beep or an out put voltage trigger some relays or LED,indicate the count is done.

  Some times  when I try to track the circuit in PCBoards some tracks hidden under ICs . or the pcb is  multi layered.that make very challenging that job. so i make this device this has two parts.  one device supply a low voltage high current pulse.the voltage is low enough to not drive any electronic components like transistor or ICs.so apply this pulse to the pcb track is safe. one ground connection with crocodile cable and other clip connect with track we need to trace. the other unit has a small magnetic picup head or loop of thick copper wire. we can use this probe by magnetically pick up the signal from the right track. even the track is in the middle layer this will trace. we can hear a tone audio in a speaker by hearing its changing pitch we can  determine the right track.  

  Some time when we forget to switch off the submersible pump then the upper tank water will be overflow until we get noticed. or some time in a middle of a bath the tank water get empty . and every day we need to switch  and carefully switch off the motor after the tank get filled  even we dont know how much water in the tank. so I design this Automatic water level controller I use Arduino nano in this project and wright a program and upload in it. Use a ultra sonic sensor for sensing water level . i fix the sensor in the lid of water tank and connect the control box with a 4 core cable. the control board has arduino nano and color LED 's for the water level the red led for indicating water level below 10% amber LED indicate water above 25% yellow is above 50% green is above 75 % when the water level goes below 10% the the ultra sonic sensor sense that level and arduino code check the main voltage. if it normal   decide to switch on the pump through a relay for a se...

 This Arduino based mini Traffic Light controller model to use in a driving school to train the students. so I make this projects for them. It simulate real traffic light sequence.

Our  home is in municipality area .There only daily  morning 5 o clock  municipal drinking water supply available for an hour. so wake up at the morning collect water at that time is a hard Job. so I make this system. my idea is collect the water first in a ground level water tank when the water reach a 90% tank level an electronic Device sense that and switch on a 1/2 HP Motor that lift the water from the Lower Tank to Upper tank. once the motor start lifting the water up it only switch off when the water level reach below 10% of Lower Tank level and also when the upper tank is full . so this process running until both the tanks fill. after both Tank fill a float valve stop further water from municipal pipe line. when  the upper tank level reach certain low level if the lower Tank is full .the motor start emptying the lower tank and lift the water to up.until the lower tank level reach 10% below at Lower tank. now the pump is off and the device waiting for the next ...

 This project is an Out put driver stage of an Arduino Project. That Can control 14 appliances some of them ON/OFF relay controls some Uses High Power MOSFET and the Out put type  is PWM. so that can Control the amount of Current to the Out put devices.such as LED strips, This board meant for controls Light , Fan and peltier cooler ,pump,Heater ,USB Power such as. The Arduino stage is not shown here

 This is an External Audio Amplifier.Its input is fed from a TV's Audio Out. customer wants this amplifier used to drive a speaker fixed in hotel bath rooms so the visitor can listen audio from the TV .and also they can controll the Volume of speaker by adjust a seprate volume  control near the speaker. it uses a stereo signal cable and power for this unit. The volume control  is used in Out put section , using multi position selector switch with proper resistor network.

This simple circuit i made to switch two motor alternatively at a preset-ted time interval for a water desalination plant.  can be preset interval time from seconds to many hours with accurate and equal running time.( this customer need a fixed time so control is omitted )

 This device i made for  one customer requirement an input dc 24voltage make the alarm beeping ON and simultaneously an big RED LED Indicator start blinking.but the alarm can be silence by a push button. but the blinking LED remains on until the 24vvolt input signal goes down. again at fault condition  when 24 v available at in put the alarm start again   

  I made this project using 2 ic's and few components it can switch on and off any load using relays.there is 4 micro switches individually  control the relay . one push make it on and next push make it off. supply voltage for this circuit is 5 to 20 volt using a voltage regulator 4 separate LED indicate the status off switch

I make this micro controller based timer as a part of shooter training Project.we can select and set time for a period of 0 t0 99 seconds or minutes. when the the timer is start.the 2 seven segment display start counting down .when it reach 0 an out put voltage activate buzzer or relay .so any electrical device can be switched on or off after a time delay   ¶ Microcontroller based design for greater accuracy and control ¶ Power supply input 12 VDC 200 mA ¶ Two 7  segments Display to display time ¶ Single key start and dual key alarm time set function ¶ Power and Relay-On LED indicator ¶ Terminal connector for connecting power supply input and relay output to the PCB ¶ Onboard regulator for regulated supply ¶ Crystal resonator based design for better accuracy there three buttons Up Down and set button