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Project: Seat Sensor System. Implemented in: Dinosaur – Disney’s Animal Kingdom Indiana Jones Adventure – Disneyland Indoors Action-adventure ride!. Presentation outline. Objective and specifications Review original design Construction and functional testing Design changes

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project seat sensor system
Project: Seat Sensor System
  • Implemented in:
    • Dinosaur – Disney’s Animal Kingdom
    • Indiana Jones Adventure – Disneyland
  • Indoors
  • Action-adventure ride!
presentation outline
Presentation outline
  • Objective and specifications
  • Review original design
  • Construction and functional testing
  • Design changes
  • Performance and reliability testing
  • Conclusions
objectives
Objectives
  • Detect presence of person and state of seatbelt
  • Display output via LED
    • State 1: Unlatched and Unoccupied
    • State 2: Latched and Occupied
    • State 3: Unlatched and Occupied
    • State 4: Fault
benefits
Benefits
  • Enhance safety features
    • Automatically verifies seat occupancy
    • Automatically verifies seatbelt state
  • Increase hourly ride capacity
    • Eliminates need for manual seat check
  • Designed around existing ride equipment
product features
Product Features
  • LED indicator
  • Counter to keep track of amount of guests
  • Affordable safety enhancement
    • No additional operators are needed
  • Potential for system expansion
    • Detect presence of person and state of seatbelt while ride is in motion
performance requirements
Performance Requirements
  • Indicates 4 states correctly
  • 99.99% reliability
  • Implemented with minimal equipment
  • Accommodate various weights
  • Waterproof and durable
original design
Original Design
  • Block diagram

Vehicle Control System

Seat Sensors

Control Logic and PLC

Guest

Operator LED Display

PLC Display

Seatbelt Sensors

Power Supply

design considerations
Design Considerations
  • Power conversion: 24VDC to 5VDC and back
  • Electrode design
  • QT310 parameter settings
  • Seat belt sensor design
  • PLC hardware and software
construction seat sensors
Construction: Seat Sensors
  • Seat sensors
    • Evaluation Board testing
    • Circuit construction with custom electrode
    • Electrode selection and testing
    • Parameter alteration
    • Integration
power conversions
Power Conversions

LM317: 28V to 4.87V

Transistor: 4.87V to 17V

construction seat belt sensors
Construction: Seat Belt Sensors
  • Seat belt sensors
    • Hall-effect sensor
    • 300 Gauss activation
    • Rated 4.75 – 24V input voltage
  • Magnet selection
    • Field strength testing
programmable logic controller plc signals
Inputs – 24V logic

4 inputs for each seat

QT310 seat sensor

Seat belt sensor

Fault

Reset

x 2 seats = 8 inputs

Outputs – 24V logic

4 states for each seat

Occupied, Latched

Occupied, Unlatched

Unoccupied, Unlatched

Fault

x 2 seats = 8 outputs

Programmable Logic Controller (PLC) Signals
construction plc
Construction: PLC
  • Read the manual
    • PLC: 600 pages
    • PLC programming software: 300 pages
    • DV-1000 Display: 200 pages
  • Wiring, programming and compilation
  • I/O and state testing
  • Debug and revise
  • Repeat
plc program
PLC Program
  • Ladder logic
    • Control relays
    • Timers
    • Counters
  • Implements
    • State decoder
    • Fault detection
    • Seat counters
construction integration
Construction: Integration
  • Interface sensors and PLC
  • Physical system construction
    • Seats and seat belts
  • Functionality testing and debugging
  • PCB and packaging
design changes fault
Design Changes: Fault
  • Original: XOR two sensors
    • BAD!
  • New: utilize heartbeat signal
    • 15us float superimposed on QT310 output, 20ms between beats
design changes fault1
Design Changes: Fault
  • PLC scan time: 20ms.
  • Fault signal period: 40ms.
  • PLC Code
    • Timer resets with Fault input.
    • “If you can count up to 5… fault.”
  • PCB power outage, fried IC will trigger fault.
design changes
Design Changes
  • Electrode
  • 24V supply outputs 28V!
    • Seatbelt sensors not rated for 28V
    • Re-calculation of power conversions
  • Counting display
    • Added counter for each seat
    • Interface with DV-1000 display
testing

Electrode Description

Max Distance to Activate Sensor

1” Diameter thin metal circular disc with holes

1.25”

2”x3” Thick metal square with holes

.63”

3.5”x3” Metal mesh screen

2”

Testing
  • Electrode
    • Range small enough so as not to detect other seats
    • Range large enough to accommodate for human movement
testing1
Testing
  • Seat sensor
    • Various weights of humans tested (45kg, 55kg, 90kg) 50 times each
      • Output independent of weight
      • 100% reliability
    • Various theme park specific objects tested
      • Book , backpack, jacket, stuffed animal, water bottle, camera, I-Pod, snow globe
      • Sensor not activated
seat belt sensor
Seat Belt Sensor
  • Reliability Testing
    • Seat belt outputs 16.7VDC when triggered
    • Data over period of 50 trials per seat belt yields 100% reliable
    • Fulfills performance requirement of triggering at least 99.9% of time
seat belt sensor1
Seat belt Sensor
  • Magnet Placement
testing water tolerance
Testing: Water Tolerance
  • 0ml-1000ml in 100ml increments
  • Soaked cotton and placed it directly on the seat.
  • Up to 3L of water.
  • With tub, up to 5L.
  • Pass!
design challenges
Design Challenges
  • PLC programming
  • Electrode selection
  • Component casualties
    • 1 voltage regulator
    • 3 QT310 chips
    • 1 latch
    • 1 resistor
    • 1 PLC output module
successes
Successes
  • Met all performance requirements!
    • Indicates 4 states correctly
    • 99.99% reliability
    • Implemented with minimal equipment
    • Accommodate various weights
    • Waterproof and durable
  • Passed all performance tests!
recommendations
Recommendations
  • Detect seat and state of seat belt while ride is in motion
  • Transmit outputs wirelessly
  • Display outputs on a computer screen instead of via LED’s
  • Automatic dispatch
conclusion
Conclusion
  • It works!
  • Thanks Mo!
  • Thanks Disney!
  • Next step:
    • Present design to Walt Disney Imagineering
    • You could be sitting on this one day…