SDCP G06 - University of Central Florida
Contents
1. which is then reflected off a target A wide angle receiver tries to detect the received signal that is reflected off the target The greatest advantage of the ultrasonic sensor is that the reflected acoustic signal is not dependant on the color of the reflecting material Also the dust and other conditions will not affect the reflected signal and it is more accurate than other type of sensor For example in case of other sensors like photoelectric sensors dust could block the photoelectric receiver The critical specification for an ultrasonic sensor 1s the distance to which the sensor can work If the measurement distance is too far the acoustic signal will be attenuated and dissipated before it reaches the receiver Some of the other parameters that need to be considered are the receiver cone which is the area where the receiver can receive the signal the repeatability of the system that need to be check to see whether the sensor can display the same value for a length of time for the same distance The accuracy of the system is also important to measure the value correctly A Final Selection The final selection sensor chosen is the Q45U Ultrasonic range finder developed by Banner Engineering Company It satisfies most of the needs in this particular project 1 Specification of Q45U Some of the features of this ultrasonic sensor are 4 e Digital filtering for exceptional immunity to electrical and acoustic noise e2. Approx 800g VHI SOFTWARE The software to program the CPU module and the LCD touch screen are provided by the company The figure below is a snap shot of the main screen of the GUI A WINDLDR The CPU model came with a software running on Windows called WINDLDR This user friendly program uses ladder logic which translate assembly language to a nice clear and understanding code Programs can be downloaded to the CPU module or upload to the computer bi directionally Online monitoring is provided to debug the program B WINDOI NV2 WINDOI NV2 is the program used to program the LCD touch screen The software provides different functionalities for communicating with the CPU module Programs can be downloaded to the LCD module or upload to the computer bi directionally Simulation of the LCD touch screen is a way to debug when no CPU module is connected OCCURANCE 5 04 09 14 01 TIME 05 04 09 OCCURANCE 05 04 09 05 04 09 RESET Y COUNTER RESET R COUNTER Fig 12 Snap shot of the main screen of the GUI IX CONCLUSION This two semester long project is a valuable experience for the group in terms of how to work in group how to conduct professional meetings and how to professionally write a technical report In the meetings contributing ideas to the group discussing various issues with engineers and going to the maintenance shop to investigate have given us valuable experience that never can be obtained from sc
3. inputs The denomination of this outputs are INO Input 0 for the first input and IN1 Input 1 for the second input VII LCD TOUCH SCREEN The HG2F model is a 5 7 LCD touch screen with a resolution of 320x240 pixels with a maximum color pallet of 256 colors The touch screen area is divided in to 192 regions making the screen able to handle up to 192 different areas to touch at one time By analyzing the table the requirements for the screen regarding the project can by checked As showed in the table below the operational voltage is 24V making it compatible with the power supply needed for the modules that will be discussed in the next chapter The operational temperature is consistent with the project having a range well over the normal temperature present in the location were the screen will be installed since it will be in the car were the driver of the monorail is located Fig 11 Appearance of HG2F LCD Touch Screen A Specification of HG2F LCD Touch Screen Po tem Description Rated Voltage 24VDC Power 10W maximum consumption at rated po voltage Momentary 10 msec Power Interruption Environmental Operation Temperature Range Operation 30 85 RH Humidity Range Storage 20 to 60 C SS Temperature Storage 30 85 RH Humidity Degree of IP65 o Allowed Altitude 0 2000 m Structural Panel cutout 162 2mm x Dimensions W 126 5mm Exterior 172mm x Dimension W x 136mm x 56mm H xD
4. their working even when the monorails are function properly A Requirements of the new sensor Based on the interactions with the monorail technicians and engineers at Disney a list of the requirements has been decided upon for the new sensor e The sensor needs to be resistant to high and low temperatures it should work in the range of OF to 155 F e As few interferences as possible from dirt accumulating on sensor face e Needs to work on a object that is moving the monorail moves at a top speed of 40 mph e The sensor should be able to operate correctly with vibration interference e The sensor should be able to sense a minimum distance of 3 to 12 inches from the sensor face e Relatively small in size preferably no smaller than existing sensor which is approximately 3 x 8 x 3 e Sensor must be able to work properly while getting wet e Sensor should not have a problem reflecting waves off of concrete or metal e Sensor should not have a problem with the surface it is sensing changing color e Needs to be able to work with different refractions i e water on the beam IV ULTRASONIC TECHNOLOGY After the research study the group came up with a solution that ultrasonic sensing technology satisfies most of the needs Ultrasonic sensors work on the principal that the system tries to detect the acoustic signals reflected off the target The sensor consists of an ultrasonic transmitter that emits an ultrasonic pulse
5. Disney Monorail Project Chun Sum Yeung Qing Chen Welsey Deschaine Thomas Monetti University of Central Florida Orlando Florida P O Box 160000 Orlando FL 32816 USA ABSTRACT The objective of this project is to identify and test a non contact type sensor technology to provide more dependable and reliable operation of the Walt Disney World monorail system The solution is expected to improve accuracy and cost effectiveness with respect to maintenance and performance The group chose this project as our senior design project because we feel we can provide a good mix of electrical and computer engineering skills to formulate a solution for Walt Disney World Index Terms Ultrasonic sensing technology non contact sensor I INTRODUCTION The Walt Disney World Monorail System is a key part of the property s transportation system It routinely carries over 100 000 passenger trips per day The trains must operate reliably to insure this level of service The system includes 12 Monorail Trains that operate over 14 lane miles of elevated beamway connecting the Magic Kingdom Epcot Ticket and Transportation Center and three resort hotels To ensure safe and smooth service for its customers the Walt Disney World Monorail Trains employ a mechanical beam contact switch to detect deflections between the train structure and the monorail beamway The existing switches are mechanical wand type switches If the train su
6. Engineering Corp Website http www bannerengineering com 5 GLOBALSPEC The Engineering Search Engine Website http www globalspec com 6 Capacitive Sensor Theory Lion Precision Noncontact Dimensional Measurement from an industry leader Website http www lionprecision com index html 7 Scott D Welsby Capacitive and Inductive Noncontact Measurement Lion Precision Inductive Website http www sensorsmag com articles 0303 capacitive 8 Serway and Beichner Physics for Scientists and Engineers with Modern Physics Fifth Edition pg588 9 Corrsys Datron Sensorsystems Inc Website http www corrsys datron com prod_sensors htm 10 Advanced Data Acquisition Corp A DAT Website http www a dat com sensor sensor_ride_height php 11 HiTech Technologies Inc Website http www hitechtech com 12 American Sensors Corp Website http www americansensors com 13 John W Sutherland Ph D CYBERMAN Education Page http www mfg mtu edu cyberman index html 14 Walt Disney World Performance Specification High Capacity Monorail Trains and Related Facilities Modifications Dec 8 1986 15 IDEC FC4A SERIES Micro Programmable Logic Controller User s Manual 16 IDEC Website http www idec com usa Qing Chen a senior electrical engineering student at University of Central Florida She is currently working with Walt Disney World for the monorail sensor project Wh
7. Selectable O to 10V dc voltage sourcing or 4 to 20mA current sourcing analog outputs e Selectable output slope positive or negative with increasing target distance e Wide operating temperature range of 25 to 70 C all models include temperature compensation e Rugged design for use in demanding sensing environments rated IEC IP67 NEMA 6P 2 Dimension of Q45U Q45U ultrasonic range finder fits the requirement of the project In figure below it shows the dimension of this sensor Transparent Cover Gasheted View Sensing Matus Quipul Load Status k Power 1 Open te Bacs 4 Push Barton Tar A Programming ol Sensing Window Limin we a Transducer ae a m j 65 0 mm wr 2 72 Pe Pd ee i k 6 4 mn 0 25 97 6 mn ae ng 4 5 mm 0 Screw Clearance 21 a T7 1mn p Internal Thread l mS A NRAN PSM 06 1 0 24 2m 6 71 Coble Extemal Thread HONK 15 Hex Mut Supplied Fig 5 Dimension of Q45U Ultrasonic Range finder V DESIGN A better approach to make the new system more cost effective in terms of its maintenance time and cost efficiency is to use two sensors on each car for the new system instead of three sensors like the existing system One sensor is to be located on one side and the other sensor is on the top Recalling from the previous sections the side switch of the existing system is to ensure a minimum distance between the switch and the monorail beamway How this method is imple
8. ge inpyt Connector 15 Gommuncaiien Connector gii _ 3 Expansion Gonmactor E 4 Powar LED PWR i 8 Run LED RUN 6 Error LED ER Ti Status LED STAT 3 input LED GCN Aad 9 Output LED TOUT or Ay 0UT 13 Cartridge Conrectar 1 14 Cartridge Connector 2 1 Power Supply Terminals 2 140 Terminals Fig 8 This is the outlook for the CPU module To be able to store data in the module an Electrical Erasable Programmable Read Only Memory EEPROM was used With a 32KB of memory the space available is good enough to store a couple of programs If in case the storage capacity is not enough to store such big programs this module would have the capability of upgrading the memory storage by adding a 64KB expansion cartridge in the specific slot in the CPU module The CPU module can handle up to seven additional modules making it capable of expansion Inside the CPU module there is also a Random Access Memory RAM used to make a back up of the data stored in EEPROM This backup will only remain for thirty minutes with a fully charged lithium battery This battery can be recharged to its maximum capacity again after running out but it would take a day to be able to do that Source wtp Wiring Fig 9 FCA D20S3 CPU Module top view with Transistor Source Output B Analog I O Module The analog I O module has fewer features from the CPU module but it still has the expansion connectors Thi
9. hool We also observe that the little pieces we have learned from engineering classes have become a big picture in reality For example in the physics study we learned about the linear coefficient expansion of different type of materials which is an issue to be considered when selecting a right sensor We have to be precise on how the temperature is related to the dimension of the monorail beamway Moreover it can be observed that different roles in the company have different responsibility The management works conceptually on projects yet the technicians have more first line information For example technicians working in the maintenance shop can locate the problems more deeply ACKNOWLEDGEMENT During this project the group gratefully appreciates the help of the following mentors and consultants for spending time with the group guiding along and providing valuable information to help the group succeed in the project We kindly thank for the help of the people Dan Welsh Jason Lovelace Robert Shmerling Bob Katz Jeff McDonnough and Leon Donovan REFERENCES 1 Donald P Massa Choosing an Ultrasonic Sensor for Proximity or Distance Measurement Massa Products Corp Website http www sensorsmag com articles 0399 0399_28 mai n shtml 2 PEPPERL FUCHS Website http www pepperlfuchs com fa sensors capacitive defa ult_e html 3 Madison Company Website http www madisonco com level ultrasonic htm 4 Banner
10. ile at University of Central Florida she had done a research on robotics under Reasearch Experience for Undergraduates program which funded by National Science Foundation in summer 2004 She is a member of Tau Beta Pi and Society for Women Engineering Chun Sum Yeung a senior student of the electrical engineering department at University of Central Florida will start to pursue his master degree here at University of a0 4 oo n Central Florida after graduated in Summer 2005 He joined Research Experience for Undergraduates REU which funded by National Science Foundation in Summer 2004 researching on robotics He is a member of Tau Beta Pi and Golden Key Thomas Monetti a senior student of the computer engineering department at University of Central Florida Going to pursue a working career in the computer engineer profession and continue studies for master degree in business administration Wesley D Deschaine is receiving his BSEE from University of Central Florida He is presently working at Lockheed Martin Simulation Training amp Support in the Components Engineering group He will be starting classes towards his MSEE in the summer of 2005 His current research interests are in power semiconductors and device modeling He is currently a student member of IEEE and PELS MRA
11. in the final deceleration of the train as well as maintaining position at stations Primary suspension of the monorail vehicles 1s provided by pneumatically inflated rubber tires operating in line atop the beamway Roll suspension and steering is provided by pneumatic type side tires which operate horizontally on the sides of the beamway Vehicles are suspended above each load tire by air bag springs which automatically inflate or deflate to adjust for varying passenger load conditions The WALT DISNEY WORLD Resort monorail system which has been in operation since 1971 currently has 12 Mark VI monorail trains that can operate at speeds of up to 45 mph Each six car train is 203 5 feet long and can carry more than 300 passengers The WDW monorail beamway track covers nearly 14 miles connecting the Magic Kingdom Epcot Ticket and Transportation Center and three resort hotels The monorails routinely carry over 100 000 passengers a day Fig 2 Simulation of a Snapshot of the Front Side of a Monorail B Monorail Beamway Description The monorail beamway is designed to supporting prestresed or post tensioned continuous beams that are regularly 110 feet long The monorail beamway is built about 60 feet off the ground The beamway is about twenty six inches wide and forty eight inches high at the beam midsection Figure 3 shows the dimension of the monorail beamway and the clearance outline Because it is made of concrete and me
12. mented is simple It s realizable that if the monorail train is leaning on one side the distance between the monorail system and the beamway will be closer on that particular side It also implies that the gap in between on the other side of the beamway is getting wider Therefore one sensor does the job for the both sides to lower the cost and maintenance time Figure 6 shows a better idea how the new approach works Modified Design Side of Beamwvay _ Monorail a wt a Sensor Enlarged Version for the Sensing Range Optimal Condition Fig 6 Modified Design for the monorail train system A double sensing range helps improve the overall system by reducing the number of sensors on each monorail train system The new design is to have one green zone two yellow zones and two red zones Green Zone stands for the system is running smoothly Yellow Zone represents the monorail train is getting closer to the beamway Maintenance procedure might be needed Red Zone means that the monorail train severely leans on either side of the monorail beamway The mid point of the green zone represents the monorail system maintaining in optimal condition If the monorail train hits to the far left red zone as in figure 7 it represents the train is leaning towards the left side of the beamway Sensor Beamva lll Side of Honorail Fig 7 The train is leaning towards the left side of the beamway Si
13. milarly the other extreme case is when the monorail train entering the red zone at the far right which means that the train is leaning towards the right side of the monorail beamway This situation is shown in Fig 8 Beamway Sensor aail Side of Honorail Fig 8 The monorail train is severely leaning towards the right of the beamway Similar solution can be seen for the side sensor to detect the distance between both sides This is how one sensor can achieve both jobs VI MICROCONTROLLER COMPONENTS The microcontroller that receives the data sent by the sensors and calculates if the distance between the monorail and the beamway is in correct range or if it needs to notify the pilot of the approaching of the monorail towards the beam and the Graphical User Interface needed to display the distances and interact with the pilot of the monorail The other components also referred as Modules are the CPU Module used to store and control the microcontroller the Analog I O Module to transform analog input to digital form and the communication adapters amp communication model to transfer data A CPU Module The CPU Module has a port 1 an RS232C port used to connect a laptop for example to download a program written in WindLDR which comes with the CPU module to accomplish data reading in to the microcontroller situated inside this Module This module also has cartridges connector allowing the chance to upgrade its
14. performance by adding more memory chips to be able to store more operations or add another clock to synchronize components of this module Figure 8 below is the communication connector that allows the CPU module to be connected with a different module The module also has a analog voltage input connector to be able to connect a analog voltage in the range of range O through 10 VDC this voltage is converted in to a number that is stored in to a data register to so it is easier to use the input For the inputs this module has an I O terminal allowing the connection of inputs and outputs to the module Another feature of this module is the power supply terminal allowing the connection of a power supply up to a value of 24DC The Expansion connector situated in upper corner of the module is used to connect the Analog to Digital I O converter used to convert the analog inputs to digital form explained later in the introduction to modules discussion This module also has the Light Emitted Diode LED making the readability of the module easier for the user including a power led to see if the power is on or off a Run led to determine if the module is running a program or not an Error led informing the user of an error occurs in the execution of the program running or in the module it self an Input led informing that a specific input is turned on and a Output led telling when a output is trigger 10 Analog Potentioneter 21 Analog Volta
15. rom that of metal The dimensions are therefore different implying the transition point is not as smooth as the rest of beamway The new design has to overcome this difficulty Obviously changing the dimension of monorail beamway can significantly affect the precision of the contact switch Therefore a non contact sensor solution is a perfect way to deal with this type of situation It can be solved by pre setting a safe range rather than a specific length so even though the length is expanded or shrunken thermally as long as it falls in the range of a safe distance the monorail train system will run smoothly and perfectly Fig 4 Monorail changes route at the transition point HI PROBLEM FORMULATION The objective of this senior design project is to research and recommend an alternative sensor technology that could perform similar functions as the existing sensor but with greater reliability and also cost lesser than the current system on maintenance After analyzing the existing sensor system several observations regarding the current system were obtained as described below e The exiting system is a beam contact switch that needs to be in contact with the monorail ensures a safe distance between the beamway and switches e The sensors are inexpensive but they are high maintenance items that need to be kept on optimum working condition for them to work e The switches are not very reliable and raise many false alarms during
16. s allows the module to be connected to the CPU module and if necessary to other I O modules since it has an Expansion Connectors on both sides It has Terminal Numbers for different inputs to be plugged in and a cable terminal to connect wires to the module The Analog I O module has a rated power voltage of 24V DC making it compatible with the CPU module that uses the same 24V for power Even if this module has a voltage rating of twenty four volts the allowed range of operation is on a minimum of approximately twenty volts and a maximum of twenty eight volts The maximum allowed voltage can reach as high to twenty eight volts since the voltage going into the module is not always twenty four volts at all times The internal current draw is about 50mA The input voltage for this module is in the range of a minimum from OV to a maximum of 10V The Analog I O module has a sample time of a 20ms where the reading time is set so for every 20ms it reads for the next set of Values passed from the sensors to this particular module This module isolates the inputs between the power circuits Figure 11 shows how the inputs are layout and where all the different connections can be made 24v DC Fuse Analog voltage current output device Analog voltage current output device Fig 10 Terminal of the analog I O module display This analog to digital input output converter has the capability of receiving a maximum of two
17. spension or tires are not in optimum condition the wand will contact the monorail beamway and signal the system There are several of these switches on each train The existing switches are a high maintenance item and may also cause false alarms There is a need to replace these switches with a system that will be both more reliable and lower in total operating and maintenance cost There are lots of new and advanced technologies for non contact available in the market such as ultrasonic microwave photoelectric magnetic capacitive and inductive sensor technologies etc Different types of technology are used in a variety of applications The biggest challenge of this project is to determine which sensing technology fits the needs of this project The prototype is funded by Walt Disney World Design and Engineering The prototype budget is 1500 including buying materials to build the prototype for testing II MONORAIL PROFILE A Monorail Train Description The Mark VI train bodies are constructed of honeycomb bonded aluminum or nomex panels Propulsion for the trains is provided by eight 100 horsepower HP and 600 VDC General Electric transit type cam controllers Braking is accomplished in two modes dynamic and hydraulic disk Air hydraulic disk brakes are located on each primary load wheel These hydraulic brakes are combined by the operator s controller with dynamic braking at approximately 7 mph and serve to assist
18. tal the beamway would expand or shrink proportionally to temperature variation Concrete has a linear expansion constant E 12 0x10 6 C The expanded or shrunken length can be calculated by the formula Ly Lo 1 E T 1 In formula 1 E is the expansion coefficient T is the temperature in degree Celsius Lo is the original length and Ly is the length under thermal interference Since temperature variation can be huge between day and night time the distance between the contact switches and the beamway may vary accordingly Similarly metal has a linear expansion constant Ey 12 1x106 C Same formula applies to length calculation under thermal interference 1 Dimension of the beamway The monorail beamway has about fourteen lane miles long It has a width of twenty six inches with two and a half between the surface of he beamway and underneath a monorail train The train enters has the outline clearance of one hundred and twenty inches wide and ninety three and a half tall The figure below shows the dimension of the monorail beamway Fig 3 The monorail beamway dimension and the clearance outline 2 Switch beam Monorail trains switch from one beamway to the other Therefore this scenario has to be under consideration when a non contact sensor is applied First the material of the monorail beamway is different changing from concrete to metal Second the expansion coefficient of concrete is different f
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