Arduino Load Testing Activity

Using Tinkercad Circuits Simulator

Introduction
This activity teaches you about electrical load testing using Arduino and various
components. You’ll learn how different loads (resistors, LEDs, motors) affect
current consumption and voltage levels in a circuit. This is a fundamental concept in
electronics and helps understand power management in real-world applications.

Learning Objectives
By the end of this activity, you will be able to:
• Understand the concept of electrical load in a circuit
• Measure current consumption using Arduino analog inputs
• Analyze how different components affect circuit performance
• Display real-time load data on an LCD screen
• Implement warning systems for overload conditions

Materials Required (In Tinkercad)

• 1x Arduino Uno R3
• 1x LCD 16x2 Display (I2C or standard)
• 1x 10kΩ Potentiometer
• 3x LEDs (Red, Yellow, Green)
• 3x 220Ω Resistors (for LEDs)
• 1x 1kΩ Resistor (current sensing)
• 3x Push buttons
• 1x DC Motor (optional for advanced testing)
• 1x Piezo Buzzer
• Breadboard and jumper wires

Circuit Design
Connection Overview
This load testing circuit uses a current sensing resistor and Arduino’s analog
input to measure the current flowing through different loads. The system displays real-
time data and provides visual and audio warnings.

Pin Connections

Component Arduino Pin Description

LCD Display SCL, SDA or D12-D7 Display load data
Current Sensor A0 Measure voltage across 1k
resistor
LED 1 (Green) D2 Normal load indicator
LED 2 (Yellow) D3 Medium load indicator
LED 3 (Red) D4 Overload indicator
Button 1 D8 Activate Load 1
Button 2 D9 Activate Load 2
Button 3 D10 Activate Load 3
Piezo Buzzer D11 Overload alarm
Test Loads D5, D6, D7 LEDs or resistors to
simulate load
Arduino Code
Copy and paste the following code into the Arduino IDE in Tinkercad:
#include <LiquidCrystal.h>

// LCD pins: RS, E, D4, D5, D6, D7

LiquidCrystal lcd(12, 13, 7, 6, 5, 4);

// Pin definitions
const int CURRENT_SENSOR = A0;
const int LED_GREEN = 2;
const int LED_YELLOW = 3;
const int LED_RED = 4;
const int BUTTON1 = 8;
const int BUTTON2 = 9;
const int BUTTON3 = 10;
const int BUZZER = 11;
const int LOAD1 = 5;
const int LOAD2 = 6;
const int LOAD3 = 7;

// Load thresholds (in mA)

const float THRESHOLD_LOW = 50.0;
const float THRESHOLD_MEDIUM = 150.0;
const float THRESHOLD_HIGH = 250.0;

// Variables
bool load1Active = false;
bool load2Active = false;
bool load3Active = false;

void setup() {
[Link](16, 2);

pinMode(LED_GREEN, OUTPUT);
pinMode(LED_YELLOW, OUTPUT);
pinMode(LED_RED, OUTPUT);
pinMode(BUZZER, OUTPUT);

pinMode(BUTTON1, INPUT_PULLUP);
pinMode(BUTTON2, INPUT_PULLUP);
pinMode(BUTTON3, INPUT_PULLUP);

pinMode(LOAD1, OUTPUT);
pinMode(LOAD2, OUTPUT);
pinMode(LOAD3, OUTPUT);

[Link]();
[Link]("Load Testing");
[Link](0, 1);
[Link]("System Ready");
delay(2000);
}
void loop() {
// Check buttons
if (digitalRead(BUTTON1) == LOW) {
load1Active = !load1Active;
digitalWrite(LOAD1, load1Active);
delay(300);
}

if (digitalRead(BUTTON2) == LOW) {
load2Active = !load2Active;
digitalWrite(LOAD2, load2Active);
delay(300);
}

if (digitalRead(BUTTON3) == LOW) {
load3Active = !load3Active;
digitalWrite(LOAD3, load3Active);
delay(300);
}

// Read current sensor

int sensorValue = analogRead(CURRENT_SENSOR);
float voltage = sensorValue * (5.0 / 1023.0);
float current = (voltage / 1.0) * 1000; // Using 1k resistor

// Update display
[Link]();
[Link]("Current: ");
[Link](current, 1);
[Link]("mA");

// Determine load status

[Link](0, 1);

if (current < THRESHOLD_LOW) {

[Link]("Status: Normal");
digitalWrite(LED_GREEN, HIGH);
digitalWrite(LED_YELLOW, LOW);
digitalWrite(LED_RED, LOW);
noTone(BUZZER);
} else if (current < THRESHOLD_MEDIUM) {
[Link]("Status: Medium");
digitalWrite(LED_GREEN, LOW);
digitalWrite(LED_YELLOW, HIGH);
digitalWrite(LED_RED, LOW);
noTone(BUZZER);
} else if (current < THRESHOLD_HIGH) {
[Link]("Status: High");
digitalWrite(LED_GREEN, LOW);
digitalWrite(LED_YELLOW, LOW);
digitalWrite(LED_RED, HIGH);
noTone(BUZZER);
} else {
[Link]("Status: OVERLOAD");
digitalWrite(LED_GREEN, LOW);
 digitalWrite(LED_YELLOW, LOW);
digitalWrite(LED_RED, HIGH);
tone(BUZZER, 1000);
}

delay(500);
}
Activity Instructions
Part 1: Building the Circuit
1. Open Tinkercad Circuits and create a new circuit project.
2. Add an Arduino Uno R3 to the workspace.
3. Add an LCD 16x2 display and connect according to the pin table.
4. Add three LEDs with 220&#x2126; resistors connected to pins 2, 3, and 4.
5. Add three push buttons connected to pins 8, 9, and 10 with pull-up configuration.
6. Create the current sensing circuit by connecting a 1k&#x2126; resistor in series
with your test loads, and connect the voltage across it to pin A0.
7. Add three test loads using LEDs with resistors on pins 5, 6, and 7.
8. Add a piezo buzzer to pin 11.
9. Double-check all connections against the pin connection table.

Part 2: Programming
10. Click on the Arduino in Tinkercad to open the code editor.
11. Switch to Text mode if not already selected.
12. Copy and paste the Arduino code provided earlier into the editor.
13. Review the code and identify the threshold values for different load levels.

Part 3: Testing
14. Click Start Simulation in Tinkercad.
15. Observe the initial display showing the system is ready.
16. Press Button 1 to activate Load 1. Record the current reading and LED status.
17. Press Button 2 to activate Load 2. Observe how the current increases.
18. Press Button 3 to activate Load 3. Watch for threshold changes.
19. Try different combinations of loads and record your observations.
20. Trigger an overload condition and observe the red LED and buzzer alarm.

Observations and Analysis

Data Collection Table
Fill in this table with your measured values:
Load Current (mA) LED Status Alarm Status
Configuration
Discussion Questions
21. What happens to the current when you activate multiple loads simultaneously?
22. Why is current sensing important in real-world electrical systems?
23. How does the 1k&#x2126; resistor help measure current in this circuit?
24. What would happen if you removed the current-limiting resistors from the LEDs?
25. Can you think of real-world applications where load testing is critical?

Extension Activities
Challenge 1: Adjustable Thresholds
Modify the code to allow users to adjust the load thresholds using a potentiometer.
Display the current threshold values on the LCD.

Challenge 2: Data Logging

Add functionality to log maximum and minimum current values over time. Display these
statistics when a specific button is pressed.

Challenge 3: Multiple Current Ranges

Implement auto-ranging by switching between different sensing resistors based on the
load magnitude, similar to a multimeter.

Challenge 4: Power Calculation

Extend the code to calculate and display power consumption in watts, using the formula
P = V &#xD7; I.

Conclusion
This activity demonstrates fundamental concepts in electrical load testing and
monitoring. Understanding how circuits respond to different loads is essential for
designing safe and efficient electronic systems. The skills you&#x2019;ve learned here
apply to battery management systems, power supplies, motor controllers, and many
other applications in modern electronics.
Remember to save your Tinkercad project and document your findings. Consider
sharing your circuit with classmates or exploring the extension activities to deepen your
understanding.
Assessment Rubric
Criteria Excellent (4) Good (3) Satisfactory Needs Work
(2) (1)
Circuit All connections Minor errors, Some errors, Major errors,
Construction correct, neat functional mostly works non-functional
layout
Code Code runs Code works Code runs but Code does not
Implementatio perfectly, well- with minor has errors run
n commented issues
Data Complete, Most data Incomplete Little to no
Collection accurate data collected, data collected data collected
with analysis accurate
Understandin Deep Good Basic Limited
g understanding understanding understanding understanding
of concepts of concepts

Additional Resources
• Tinkercad Circuits Tutorial: Learn more about circuit simulation
• Arduino Reference: Official documentation for Arduino functions
• Ohm&#x2019;s Law Calculator: Practice voltage, current, and resistance
calculations
• LCD Display Guide: Learn advanced LCD programming techniques

Safety Notes for Physical Implementation

If you build this circuit with real components:
• Always check polarity of components before powering on
• Use appropriate current-limiting resistors for all LEDs
• Do not exceed the Arduino&#x2019;s maximum current rating of 40mA per pin
• Disconnect power before making circuit modifications
• Work in a well-ventilated area and avoid touching hot components