Senior Design II Spring 2001 Group 19 Guest Sensing in Guest Vehicles Dave Huber - Project Leader...

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Senior Design II

Spring 2001

Group 19

Guest Sensing in Guest VehiclesGuest Sensing in Guest Vehicles

Dave Huber - Project Leader

Christina Fleming - Administrative Leader

Zaw Tun - Technical Leader

Kevin Kerkvilet - Technical Leader

Sponsored by Walt Disney World Sponsored by Walt Disney World Ride and Show EngineeringRide and Show Engineering

Group 19

Original SpecsOriginal Specs• A guest sensing system that can be used in guest vehicles

in order to monitor guests on The Haunted Mansion ride at Walt Disney World.

• A system that can replace or enhance the current monitoring system.

• Designed with intentions to utilize on other attractions in the future.

# 20 # 2 # 1

. . . . . . . .

Current SystemCurrent System

• Lap bar used to keep guests in their seats• Pressure mats strategically placed around the ride

– Connected to a main controller

– Output to ride personnel

– Issues• No monitoring until guest leaves vehicle

• Leaves gaps in coverage

• Guests must reach mat before action occurs

• All audio loaded from outside the ride vehicles

Onboard System FocusOnboard System Focus

• Leaving the vehicle is already covered in an effective manner with pressure mats

• Entire system contained onboard the ride

• Monitoring the internal actions of guests will add new features to overall system.

Design GoalsDesign Goals

• Replace and/or enhance older system that is currently in place

• Prevent situations before they develop • Protect as many situations as possible• Create a long lasting and reliable system• Built in redundancy• Build a cost effective solution • Easy installation and low maintenance

Main Block DiagramsMain Block DiagramsVehicle with detection

system enabledAlarmWDW Guests

Basic Block Diagram

WDW Guest in vehicle WarningAlarmGuest leaning

outside vehicle

Guest leaving the vehicle

Security Alarm

Guest standing in vehicle

System Flowchart

OutputPLC

ControllerInput Sensors

Basic System Pieces

System System StoryboardStoryboard

Unloading Procedure for Guests Exiting the

Loading Procedure for Guests Entering Ride

Ride Vehicles Leaving Loading Area

Ride Vehicles Entering Unloading Area

Monitoring System Engaged

Monitoring System Disengaged

If Guest Detected By

Warning System

If Guest Detected By

Security System

Warning Procedure Will Be Activated

Security Procedure Will Be Activated

Main ScenariosMain Scenarios

• Standing up inside of the ride vehicle

• Leaning outside of ride vehicle

• Leaving the ride vehicle

Christina FlemingChristina Fleming

TECHNOLOGY

Seat SensorsSeat Sensors

• Placement of sensors• Easily incorporated into current system• Allow warning system• Protected vinyl casing

Seat Sensor ComparisonSeat Sensor Comparison

X X X X X X XBend Sensor

X X XStrain Gage

X X X X XOccupant Seat Sensor

Cost effective

Variations in temperature

RobustReliableEase of Installation

Easily maintained

Measured total weight on seat

Type of Sensor

Bend SensorsBend Sensors• What they are:

– Ultra-thin plastic film that changes electrical conductivity as the sensor is bent

– Light weight (about 90% smaller than average sensor)

– Longer life span

– No mechanical components

• How they work:– Measure up to 200 data points per inch to detect changes in the occupant’s position

– Conductive ink within film will generate weight pattern signals when bent

– Acts as it’s own spring to return to original position

– Operate without manual activation and can be activated up to 5 million times

• How we will use them:– Incorporated underneath seat structure between foam and vinyl

– 12 sensors per seat making up 6 zones (minimum 2 zones per person)

– Measure overall positioning on entire seat

– Compare initial data to data taken throughout travel of ride

– This comparison will take place in PLC were initial data will be stored

Seat LayersSeat Layers

Fiberglass SupportFoam Pad

Vinyl Covering

Bend Sensor Layout

Bend Sensor LayoutBend Sensor Layout

Added Pivot Point

Connector

Potentiometer

Flexpoint Bend Sensor

Alignment of Bend Sensors for Entire Seat

Ride Seat

ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6

Per Person

Three People on Seat

Bend Sensor SpecsBend Sensor Specs

• Life Cycle >1 million cycles

• Temperature Range -35 deg C to +85 deg C

• Input Voltage 12volts

• Base Resistor 100ohm - 500kohm

• Resistance 6kohm - 11kohm

• Weight (3”) .11 grams

• Output Voltage Varies

Zaw TunZaw Tun

INPUT SENSORS &

AUDIO SYSTEM

On/Off Magnetic SwitchOn/Off Magnetic Switch

• Why we need On/Off switch– Turns onboard system on after leaving

loading area– Turns onboard system off after entering

unloading area• Magnetic• 506WG OPEN (GRI Corp)• Very Small• Easy Installation• Inexpensive and reliable system

On/Off Switch SchematicOn/Off Switch Schematic

Part Number Loop Type Maximum Initial Contact Resistance

Maximum Switching Voltage

Maximum Switching Current

506 WG OPEN .100 175VDC .25A

505WG CLOSED .150 200VDC .50A

On/Off Switch PlacementOn/Off Switch Placement

Lap bar is closed, magnetic on/off switch is in the ON position

Lap bar is up, magnetic on/off switch is in the OFF position

Sensor Durability Reliabilityfor oursystem(Less False

Alarm Rate)

Ease ofImplementation

Ease ofmaintenance

InfraredSensor(MotionDetector)

CoaxialCable x xMicrowaveSensors x x xUltrasonicSensors x x x xPhotoElectricBeamSensor

x x x x x

Sensor Comparison ChartSensor Comparison Chart

Lean SensorLean Sensor

•QS12VP6R (Receiver) (Banner Engineering Corp)•QS126E (Emitter)•10V-30Vdc @ less than 25mA•Output response 600 microseconds for excellent sensing•Dark Mode•Output Configuration

•Protect against false pulse (e.g., power-up & continuous overload)•Operating condition

•Temp –4 to +131 F•Supply Protection Circuitry

•Protected against reverse polarity & transient voltage

Reasons for Choosing Specific ModelReasons for Choosing Specific Model

• Easily fit almost any mounting

• Small in size

• Opposed Mode(Emitter & Receiver)– Less interference (Lower false alarm rate)

• Can adjust sensitivity with single push button

• Easy Connection– Comes in various length of wire with pigtail Quick Connector

Lean Sensor PlacementLean Sensor Placement

ISD1000A SpecificationISD1000A Specification

– Zero-power message storage• Eliminate battery backup circuit

– Used Two connection for power(+5V) and ground to minimize the noises.

– Dc Operating Conditions• VccD = VccA = 5V

• Operating Temperature = 77°F (25°C)

• VssD + VssA = 0V

• Operating Supply current (VccA + VccD )– PD=0…………………………………………….25 mA

• Standby Supply Current (VccA + VccD )– PD = 1, P/ R = 1………………………………….10uf

• Speaker Output Load Impedance……………16 Ohms

ISD1000A Record/Play ChipISD1000A Record/Play Chip

• Easy-to-use single-chip voice record/playback solution

• High-quality, natural voice/audio reproduction

• Manual switch or Microcontroller compatible Playback

• Automatic power-down

• Full addressable to handle multiple messages

• 100-year message retention

• 100,000 record cycles

• On-chip clock source

• Programmer Support for Play-only circuit

Play/Record CircuitPlay/Record Circuit

Passive Component FunctionPassive Component FunctionPart Function Comments

R1 Microphone power supplydecoupling

Reduces power supply noise

R2 Release time constant Sets release time for AGC(Automatic Gain Control)

R3 Microphone Biasing Resistor Provides biasing for microphoneoperation.

R5,R6 Series limiting resistors Reduces level to preventdistortion at higher supplyvoltages.

C1,C5 Microphone DC-blockingcapacitor Low-frequency cutoff

Decouples microphone bias fromchip. Provides single pole low-frequency cutoff and commonmode noise rejection.

C2 Attack/Release time constant Sets attack/release time for AGC

C3 Low-frequency cutoff capacitor Provides additional pole for low-frequency cutoff

C4 Microphone power supplydecoupling

Reduces power supply noise

C6,C7,C8

Power supply capacitors Filter and bypass of power supply

Play Only CircuitPlay Only Circuit

Dave HuberDave Huber

Programmable Logic Controller

Programmable Logic Programmable Logic Controller (PLC)Controller (PLC)

• Brain of system

• Controls reactions of system

• Allows timing delays for improving performance by adding built-in redundancy, and allowing for many special features

• Provides an easily modified software program for debugging and implementing desired features

PLC SpecsPLC Specs

• Direct Logic 105– Allows 10 inputs– Allows 8 outputs

• Programmed with ladder logic on personal computer

• 12 Volt DC power supply

Power Input Lines

Output Lines

On/Off Sensor

Bend Sensors (# 3)

Bend Sensors (# 2)

Bend Sensors (# 1)

Lean Sensors

Warning Message

LED #1

Bend Sensors (# 6)

Bend Sensors (# 5)

Bend Sensors (# 4)

LED #2

LED #3

PLC LayoutPLC Layout

Error LED

PLC Lean Sensor FlowchartPLC Lean Sensor Flowchart

NO If On/Off Switch is ON

If Left Lean Sensor Signal

is Active

Audio Warning Alarm

Reset Delay

If Right Lean Sensor Signal

is Active

If Right Lean Sensor Signal

is Active

Delay 2 seconds Before Next Check

If Left Lean Sensor Signal

is Active

Delay 2 seconds Before Next Check

PLC Seat Sensor PLC Seat Sensor FlowchartFlowchart

If On/Off Switch is ON

Read, Calculate and Compare Current Total

From Seat Sensor

If Current Total is Less Than Initial Total

Read, Calculate and Store Initial Total of Guests

From Seat Sensors

Delay Before Next Check

If Current Total is Less Than Initial Total

Read Calculate and Compare Current Total

From Seat Sensors

Audio Warning Alarm

Reset Delay

Clock Cycle Delay

Kevin KerkviletKevin Kerkvilet

Hardware Space &Power Requirements

Implementation RequirementsImplementation Requirements

• Hardware Space– There must be a free area to place our new hardware

components

• Generated Power– The total generated power must be greater then the total

required power for each component

• Audio Output– The current system must allow an interrupt into the audio

system for a warning message

Hardware SpaceHardware Space

• Goals

• Seat Cushion

• Ribbon Cable

• Serial Cable

• Boxes

GoalsGoals

• We don’t want to change the appearance of the ride

• The PLC and circuits need to be stored somewhere safe and easy to access

• Maintenance of the system should be familiar to the current system emplaced (Just extra boxes to check)

The SeatThe Seat

• There is a circular hole in the middle of the seat.

• The connector from the Flex Point Bend Sensors were wired to the middle of the seat cushion to meet the requirements.

Ribbon CableRibbon Cable

• The six zones were wired using ribbon cable• The seat cushion was drilled wide enough in the

circular area of the seat to feed the cable through

Wooden SupportFoam Pad

Vinyl Covering The Bend Sensors Wired

Ribbon connector is mounted on the wood.

Serial CableSerial Cable

• The ribbon cable is mounted to the seat to allow an easy way to remove the seat cushion

• The serial cable gives a sturdy connection from the seat to the PLC Serial Cable

BoxesBoxes

• The dimensions of the box is approximately 15” x 6” x 6”

• The boxes are big enough to hold all our hardware and are hidden underneath track

# 20 # 2 # 1

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Hardware Components Current Power Supply (Alternator)

String of CarsString of Cars

Serial Cable

PLC PowerPLC Power

• The seat circuit, on/off switch, lean sensors, and audio message are power dependent of the PLC

• Needs to be measured for total amps across the inputs to find total needed power for the system

• One alternator is used to power 20 cars• Total system amperage needed is approximately

300mA per system (per car)

Audio RequirementsAudio Requirements

• For demonstration purpose only

• The main concept lies in connecting our output into the existing Disney sound system that the cars already have

• Main mission is to set up detection system that will prevent a guest from leaving a moving vehicle

Audio OptionsAudio Options

• Setup a switching circuit between the speakers among Disney’s current audio and the PLC audio message

• Another possibility would be to have a way to have the PLC audio message to override the Disney audio via higher FM transmission

Future ExpansionsFuture Expansions

• RFID Communications– Will be able to communicate information to and

from each vehicle

• Database – Collect data from the PLC to predict guest

movement during a ride.

Main Parts List Cost Per. Qty. Needed Actual CostsTest Seat $0.00 1 $0.00

PLC $200.00 1 $0.00Leaning Sensor $60.00 2 $0.00

Seat Sensor $0.50 10 $0.00Power Supply $13.00 1 $13.00On/Off Sensor $5.00 1 $0.00

Audio Chip $3.00 1 $0.00Ribbon Cable $4.00 1 $4.00Serial Cable $10.00 1 $10.00

Cable Connectors $1.25 2 $2.50Wire - $0.00

Breadboard $2.39 2 $2.39Resistors $0.10 12 $0.00

Variable Resistors $0.50 6 $3.00Quad Comparator $1.00 2 $2.00

Screws/Nuts $0.83 1 $0.83Wood $3.66 2 $3.66Glue $2.00 1 $2.00

Seat Cover $3.00 1 $3.00Mini Speaker $2.29 1 $2.29

Sub-total $48.67

Travel Expenses $250.00Printer Paper $15.00

Copies $10.00

OVERALL TOTAL $323.67

Prototype Costs

Implementation CostsImplementation CostsMain Parts List Cost Per. Qty. Needed Estimated Costs

PLC $100.00 180 $18,000.00Leaning Sensor $60.00 360 $21,600.00

Seat Sensor $0.50 2160 $1,080.00Power Supply $0.00 - $0.00On/Off Sensor $2.50 180 $450.00

Audio Chip $3.00 180 $540.00Serial Cable $5.00 180 $900.00

Cable Connectors $1.25 360Wire -

Circuit Board $2.00 360 $720.00Resistors $0.05 2160 $108.00

Variable Resistors $0.50 1080 $540.00Quad Comparator $1.00 360 $360.00

Capicitors $0.05 360 $18.00Voltage Regulator $0.50 180 $90.00

OVERALL TOTAL $44,406.00

Work DistributionWork Distribution

PLC Seat Sensors Audio Board Input Sensors(Magnetic, Photoelectric)

PowerRequirements

HardwarePlacement

CHRISTINAx

ZAWx x

KEVIN x x

Meet w/ Flexpoint - Bend Sensors 0 days 1/4/01 8:00 1/4/01 8:00 100%

Measurements from ride 1 day 1/5/01 8:00 1/5/01 17:00 100%

Initial testing on Bend sensors 1 day 1/10/01 8:00 1/10/01 17:00 100%

Obtain PLC and tutorial 1 day 1/15/01 8:00 1/15/01 17:00 100%

Initial PLC wiring and test 3 days 1/15/01 8:00 1/17/01 17:00 100%

Status report #1 16 days 1/1/01 8:00 1/22/01 17:00 100%

Create CDR slides 12 days 1/26/01 8:00 2/12/01 17:00 100%

CDR Presentation 0 days 2/2/01 8:00 2/2/01 8:00 100%

Second Bend sensor test-layout 6 days 2/5/01 8:00 2/12/01 17:00 100%

Meeting w/ photoelectric rep 1 day 2/12/01 8:00 2/12/01 17:00 100%

Circuit Redesign 3 days 2/12/01 8:00 2/14/01 17:00 100%

Audio/Power requirements meeting 1 day 2/15/01 8:00 2/15/01 17:00 100%

Implement circuit redesign 7 days 2/26/01 8:00 3/6/01 17:00 100%

90% Design Review 1 day 3/19/01 8:00 3/19/01 17:00 100%

Purchase Prototype parts 1 day 3/19/01 8:00 3/19/01 17:00 100%Choose lean sensor from samples 3 days 2/28/01 8:00 3/2/01 17:00 100%Program PLC 44 days 1/29/01 8:00 3/29/01 17:00 100%Finialize Layout of Bend Sensors 0 days 3/9/01 8:00 3/9/01 8:00 100%Assemble Seat Structure 5 days 4/2/01 8:00 4/6/01 17:00 100%Record and Implement Audio Chip 7 days 4/2/01 8:00 4/10/01 17:00 100%Debug PLC 7 days 4/2/01 8:00 4/10/01 17:00 100%Mount Audio Board/Speaker 1 day 4/12/01 8:00 4/12/01 17:00 100%Create Test Plan 1 day 4/13/01 8:00 4/13/01 17:00 100%Final Design Review 0 days 3/9/01 8:00 3/9/01 8:00 100%System Testing 15 days 3/5/01 8:00 3/23/01 17:00 100%Documentation 45 days 2/26/01 8:00 4/27/01 17:00 75%User Manual 25 days 3/26/01 8:00 4/27/01 17:00 10%

Work ChartWork Chart

Senior Design II Spring 2001 Group 19 Guest Sensing in Guest Vehicles Dave Huber - Project Leader...

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