Senior Design II
Spring 2001
Group 19

Group 19
Dave Huber - Project Leader
Christina Fleming - Administrative Leader
Zaw Tun - Technical Leader
Kevin Kerkvilet - Technical Leader
Sponsored by Walt Disney World
Ride and Show Engineering

• 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
. . . . . . . .

• 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

• 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.

• 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

WDW Guests
Basic Block Diagram
Vehicle with detection system enabled
Alarm
WDW Guest in vehicle
System Flowchart
Guest standing in vehicle
Guest leaning outside vehicle
Guest leaving the vehicle
Warning
Alarm
Security
Alarm
Basic System Pieces
Input
Sensors
PLC
Controller
Output

Loading Procedure for
Guests Entering Ride
Ride Vehicles Leaving
Loading Area
Monitoring System
Engaged
If Guest Detected By
Warning System
YES
Warning Procedure
Will Be Activated
If Guest Detected By
Security System
YES
Security Procedure
Will Be Activated
Ride Vehicles Entering
Unloading Area
Unloading Procedure for Guests Exiting the
Ride
Monitoring System
Disengaged

• Standing up inside of the ride vehicle
• Leaning outside of ride vehicle
• Leaving the ride vehicle

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

Type of
Sensor
Measured total weight on seat
Easily maintained
Ease of
Installation
Reliable Robust Variations in temperature
Cost effective
Occupant
Seat
Sensor
Strain
Gage
X
X
X X
X
X
X
X
Bend
Sensor X X X X X X X

• 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

Vinyl Covering
Bend Sensor Layout
Foam Pad Fiberglass Support

Flexpoint Bend Sensor
Potentiometer
Added Pivot
Point
Connector
Alignment of Bend Sensors for Entire Seat
ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6
Per Person
Three People on Seat
Ride Seat

• Life Cycle
>1 million cycles
• Temperature Range-35 deg C to +85 deg C
• Input Voltage
• Base Resistor
12volts
100ohm - 500kohm
• Resistance
• Weight (3”)
• Output Voltage
6kohm - 11kohm
.11 grams
Varies

•
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

Part Number Loop Type
506 WG
505WG
OPEN
CLOSED
Maximum Initial
Contact Resistance
Maximum
Switching Voltage
Maximum Switching
Current
.100
.150
175VDC
200VDC
.25A
.50A

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 Reliability for our system
(Less False
Alarm Rate )
Infrared
Sensor
(Motion
Detector)
Coaxial
Cable x x
Microwave
Sensors x
Ultrasonic
Sensors x
Ease of
Implementation
Ease of maintenance
Cost x x x x x x x x
Photo
Electric
Beam
Sensor x x x x x

•
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

•
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

–
Zero-power message storage
• Eliminate battery backup circuit
– Used Two connection for power(+5V) and ground to minimize the noises.
– Dc Operating Conditions
• Vcc
D
= Vcc
A
= 5V
• Operating Temperature = 77°F (25°C)
• Vss
D
+ Vss
A
= 0V
• Operating Supply current (Vcc
A
+ Vcc
D
)
– PD=0…………………………………………….25 mA
• Standby Supply Current (Vcc
A
+ Vcc
D
)
– PD = 1, P/ R = 1………………………………….10uf
• Speaker Output Load Impedance……………16 Ohms

• 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

Part Function
R1
R2
Microphone power supply decoupling
Release time constant
Comments
Reduces power supply noise
Sets release time for AGC
(Automatic Gain Control)
R3 Microphone Biasing Resistor
R5,R6 Series limiting resistors
C1,C5 Microphone DC-blocking capacitor Low-frequency cutoff
C2 Attack/Release time constant
Provides biasing for microphone operation.
Reduces level to prevent distortion at higher supply voltages.
Decouples microphone bias from chip. Provides single pole lowfrequency cutoff and common mode noise rejection.
Sets attack/release time for AGC
C3 Low-frequency cutoff capacitor Provides additional pole for lowfrequency cutoff
Reduces power supply noise C4
C6,C7,
C8
Microphone power supply decoupling
Power supply capacitors Filter and bypass of power supply

• 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

• Direct Logic 105
– Allows 10 inputs
– Allows 8 outputs
• Programmed with ladder logic on personal computer
• 12 Volt DC power supply

Lean Sensors
Bend Sensors (# 1)
Bend Sensors (# 2)
Bend Sensors (# 3)
Bend Sensors (# 4)
Bend Sensors (# 5)
Bend Sensors (# 6)
On/Off Sensor
LED #1
LED #2
LED #3
Error LED
Warning Message
Power
PLC
Input Lines
Output Lines

NO If On/Off Switch is ON
YES
If Left Lean
Sensor Signal is Active
NO
YES
Delay 2 seconds Before
Next Check
If Right Lean
Sensor Signal is Active
YES
Delay 2 seconds Before
Next Check
NO
NO
If Left Lean
Sensor Signal is Active
YES
If Right Lean
Sensor Signal is Active
YES
Audio Warning Alarm
NO
Reset Delay

Clock Cycle Delay
NO
If On/Off Switch is ON
YES
Read, Calculate and Store
Initial Total of Guests
From Seat Sensors
Read Calculate and
Compare Current Total
From Seat Sensors
NO
If Current Total is Less
Than Initial Total
YES
Delay Before
Next Check
Read, Calculate and
Compare Current Total
From Seat Sensor
If Current Total is Less
Than Initial Total
Reset Delay
Audio Warning Alarm
YES

• 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

• Goals
• Seat Cushion
• Ribbon Cable
• Serial Cable
• Boxes

• 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)

• 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.

• 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
Vinyl Covering
The Bend Sensors Wired
Foam Pad
Ribbon connector is mounted on the wood.
Wooden Support

• 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

• 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
Serial Cable
. . . . . . . .
# 2 # 1
Hardware Components Current Power Supply
(Alternator)

• 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)

• 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

• 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

• 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.

Prototype Costs
Main Parts List
Test Seat
PLC
Leaning Sensor
Seat Sensor
Power Supply
On/Off Sensor
Audio Chip
Ribbon Cable
Serial Cable
Cable Connectors
Wire
Breadboard
Resistors
Variable Resistors
Quad Comparator
Screws/Nuts
Wood
Glue
Seat Cover
Mini Speaker
Cost Per.
$0.00
$200.00
$60.00
$0.50
$13.00
$5.00
$3.00
$4.00
$10.00
$1.25
$2.39
$0.10
$0.50
$1.00
$0.83
$3.66
$2.00
$3.00
$2.29
Qty. Needed
1
1
2
6
2
2
-
2
12
1
1
1
1
1
2
10
1
1
1
1
Sub-total
Travel Expenses
Printer Paper
Copies
OVERALL TOTAL
Actual Costs
$0.00
$2.50
$0.00
$2.39
$0.00
$3.00
$2.00
$0.83
$3.66
$0.00
$0.00
$0.00
$13.00
$0.00
$0.00
$4.00
$10.00
$2.00
$3.00
$2.29
$48.67
$250.00
$15.00
$10.00
$323.67

Main Parts List
PLC
Leaning Sensor
Seat Sensor
Power Supply
On/Off Sensor
Audio Chip
Serial Cable
Cable Connectors
Wire
Circuit Board
Resistors
Variable Resistors
Quad Comparator
Capicitors
Voltage Regulator
Cost Per.
$100.00
$60.00
$0.50
$0.00
$2.50
$3.00
$5.00
$1.25
$2.00
$0.05
$0.50
$1.00
$0.05
$0.50
Qty. Needed
180
360
2160
-
180
180
180
360
-
360
2160
1080
360
360
180
Estimated Costs
$18,000.00
$21,600.00
$1,080.00
$0.00
$450.00
$540.00
$900.00
$720.00
$108.00
$540.00
$360.00
$18.00
$90.00
OVERALL TOTAL $44,406.00

DAVE
CHRISTINA
PLC Seat Sensors Audio Board Input Sensors
(Magnetic, Photoelectric)
Power
Requirements
Hardware
Placement x x
ZAW x x
KEVIN x x

Meet w/ Flexpoint - Bend Sensors
Measurements from ride
Initial testing on Bend sensors
Obtain PLC and tutorial
Initial PLC wiring and test
Status report #1
Create CDR slides
Status report #2
CDR Presentation
Status report #3
Second Bend sensor test-layout
Status report #4
Meeting w/ photoelectric rep
Circuit Redesign
Audio/Power requirements meeting
Status report #5
Status report #6
Implement circuit redesign
Status report #7
90% Design Review
Purchase Prototype parts
Choose lean sensor from samples
Program PLC
Finialize Layout of Bend Sensors
Assemble Seat Structure
Record and Implement Audio Chip
Debug PLC
Mount Audio Board/Speaker
Create Test Plan
Final Design Review
System Testing
Documentation
User Manual
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