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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
YES
YES
Unloading Procedure for Guests Exiting the
Ride
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
SEAT
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
Cost
InfraredSensor(MotionDetector)
x x x
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
PLC
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
NOYES
NO
YES
NO
YES
NO If On/Off Switch is ON
If Left Lean Sensor Signal
is Active
NO
YES
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
YES
If Left Lean Sensor Signal
is Active
Delay 2 seconds Before Next Check
PLC Seat Sensor PLC Seat Sensor FlowchartFlowchart
YES
NO
YES
YES
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
NO
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
. . . . . . . .
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
DAVEx
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%
Status report #2 6 days 1/22/01 8:00 1/29/01 17:00 100%
CDR Presentation 0 days 2/2/01 8:00 2/2/01 8:00 100%
Status report #3 6 days 1/29/01 8:00 2/5/01 17:00 100%
Second Bend sensor test-layout 6 days 2/5/01 8:00 2/12/01 17:00 100%
Status report #4 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%
Status report #5 6 days 2/12/01 8:00 2/19/01 17:00 100%
Status report #6 6 days 2/19/01 8:00 2/26/01 17:00 100%
Implement circuit redesign 7 days 2/26/01 8:00 3/6/01 17:00 100%
Status report #7 6 days 2/26/01 8:00 3/5/01 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
