Tasked with replacing the motion PC in The Drexel Ride simulator with something newer, modular, and easier to repair, our senior design group began researching solutions. First, we read all of the available
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documentation that came with the ride. The Drexel Ride came with an operating manual and three sheets of incomplete, inadequate, unexplained schematics. Fortunately, the distribution panel that the motion
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PC is wired to has some labeling that is somewhat informative, so we were able to discern where some
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the of signals are routed and where we were would be able to tap into for signals. The distribution panel
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is shown below:
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W n by e nc rre Te
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The motion PC has four 50-pin ribbon cables that plugged into four different sections of the distribution panel: WIM-301 and WIM-302 for digital I/O,
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Figure 2. WIM-301
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W n by e nc rre Te Figure 3. WIM-302
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WIM-303 for analog input,
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W n by e nc rre Te Figure 4. WIM-303
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and WIM-304 for analog output.
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W n by e nc rre Te Figure 5. WIM-304
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Their corresponding locations on the schematic are shown below:
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Figure 6. Schematic for WIM-301
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Figure 7. Schematic for WIM-302
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W n by e nc rre Te Figure 8. Schematic for WIM-303
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W n by e nc rre Te Figure 9. Schematic for WIM-304
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Matching their corresponding alphanumeric labels to the schematic allowed us to figure out what each terminal does:
WIM-301 WIRE# TERMINAL CHANNEL 30038 15 0 319 13 1 E-STOP 11 2 30032 9 3 30033 7 4 30804 5 5 30028 3 6 30811 1 7
INPUTS OUTPUTS
E-STOP E-STOP E-STOP E-STOP 308A 308A CR3082 30621 SPARE
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Table 1. WIM-301 Connections
TERMINAL 16 14 12 10 8 6 4 2
WIRE# 309 309 309 309 309 309 309 309
FUNCTION DOOR CLOSED TAPE SWITCH OK E-STOP LINE LEFT SEAT BELT LOCKED RIGHT SEAT BELT LOCKED UNUSED GONDOLA RIDE PUSHBUTTON OIL TEMPERATURE OK
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0 1 2 3 4 5 6 7
37 34 31 28 25 22 20 18
315 316 317 318 30007 30040 320 SPARE
PITCH ENABLE ROLL ENABLE LIFT ENABLE BLOCKING ENABLE DOOR CLOSE ENABLE DOOR OPEN ENABLE MC E-STOP OUTPUT
Wire 309 connects to COM A, which is the negative side of the +24 V PS, and wire 308A connects to the
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E-STOP bus. Even though it is not very clear in the schematic, we were able to decipher that E-STOP is a +24 VDC bus what provides power to various sections of the distribution panel by matching the output of the +24 V power supply (PS):
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to the input of the E-STOP line:
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Figure 11. Schematic for E-STOP Line
The E-STOP bus is enabled by the Emergency Stop button on the control panel:
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Figure 12. Control Panel
The output of the E-STOP BUS line goes to many other places from here. Table 2. WIM-302 Connections
INPUT S
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WIM-302
WIRE# TERMINAL CHANNEL TERMINAL WIRE# FUNCTION 30618 15 0 16 309 NORMAL MODE SELECTED
13 11 9 7 5 3 1
1 2 3 4 5 6 7
14 12 10 8 6 4 2
309 309 309 309 309 309 309
308A 308A 308A 308A 308A 308A 308A SPARE
36 33 30 27 24 21 19 17
0 1 2 3 4 5 6 7
37 34 31 28 25 22 20 18
30615 30607
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OUTPUTS
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30619 SPARE 30616 30608 30622 30614 30617
30609 30610
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30624 SPARE
DEMO MODE SELECTED SPARE HOME BUTTON RUN BUTTON E-STOP BUTTON E-STOP RESET BUTTON CLOSE DOOR SWITCH
RUN BUTTON LIGHT GONDOLA RIDE STOP LIGHT DOOR CLOSED LIGHT RESTRAINTS OK LIGHT E-STOP RESET LIGHT
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For WIM-302, just as with WIM-301, wire 308A is the E-STOP bus (which is +24 V) and wire 309 is COM A. Table 3. WIM-303 Connections
WIRE# TERMINAL NONE 2 NONE 4 NONE 6
CHANNEL 0 1 2
WIM-303 TERMINAL 3 5 7
WIRE# 313 313 313
FUNCTION PITCH POSITION ACTUAL ROLL POSITION ACTUAL LIFT POSITION ACTUAL
Wire 313 is COM B, which is the negative side of the ±12 V, +5 V PS.
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Figure 13. ±12, +5 V PS
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This power supply has a -5 V output that is not used in this application. Table 4. WIM-304 Connections
I/O
WDT+
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WIRE# TERMINAL 30105 2 30115 4 30123 6
CHANNEL 0 1 2 0
WIM-304 TERMINAL WIRE# 3 30106 5 30114 7 30124 40 50
321 WDT-
FUNCTION PITCH DRIVE COMMAND ROLL DRIVE COMMAND LIFT DRIVE COMMAND WATCHDOG TIMER GND
Terminal 50, WDT-, is the equipment ground, which is different from the common of the power supplies.
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There is a 50-60 mV difference between the power supplies’ common and ground. This difference means that when wiring up a new piece of equipment to the distribution panel, we will have to make sure not to tie either common to the ground, or the common from either power supply to each other.
There are eight relays on the distribution panel; six are labeled on that panel, but only four are
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noted in the schematics. The four in the schematics are:
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As shown in the figure, CR303, CR304, CR305, and CR306 enable the pitch, roll, lift, and
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blocking, respectively.
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Figure 14. Schematic for Control Relays
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These are IDEC Corporation, model RR2P-ULDC24V, octal relays.
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Figure 15. Control Relay
These relays use terminal 2 (-, COM A) and 7(+, E-STOP BUS) to energize the solenoid in the relay, then the path through the relay switches from terminals 1-4 to terminals 1-3.
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There are six of these labeled relays:
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Figure 16. CR301
30621 320 30620
FUNCTION
24V
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TERMINAL 1 2 3 4 5 6 7 8
CR-301 WIRE# PD BUS 309 E-STOP BUS
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Table 5. CR301 Pinout
Figure 17.CR303
Table 6. CR 303 Pinout
CR-303 WIRE# E-STOP BUS 309 30108
FUNCTION E-STOP BUS COM A
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TERMINAL 1 2 3 4 5 6 7 8
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Table 7. CR304 Pinout
CR-304 WIRE# E-STOP BUS 309 30117
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FUNCTION E-STOP BUS COM A
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TERMINAL 1 2 3 4 5 6 7 8
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Figure 18. CR304
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Table 8. CR305 Pinout
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FUNCTION E-STOP BUS COM A
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TERMINAL 1 2 3 4 5 6 7 8
CR-305 WIRE# E-STOP BUS 309 30126
Table 9. CR306 Pinout
TERMINAL 1
CR-306 WIRE# E-STOP BUS
FUNCTION E-STOP BUS
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Figure 20. CR306
309 30009
COM A
318
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2 3 4 5 6 7 8
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30045
FUNCTION COM A
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TERMINAL 1 2 3 4 5 6 7 8
CR-307 WIRE# 308A 30046 319
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Figure 21. CR307
Each relay is used simply in this application; to allow +24 V to pass when the enable signal comes from the motion PC.
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After this thorough, lengthy inspection of the distribution panel, we realized we could replace the motion PC by disconnecting it from the distribution panel and wiring in a CompactRIO (CRIO) to the panel
instead. We wrote a proposal to National Instruments and they approved our request, sending us a model 9076 CRIO, and four modules that can replicate the motion PCs controls to the distribution panel.
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W n by e nc rre Te Figure 22. CompactRIO, Model 9076
We requested two digital input/output modules (NI 9403), which will connect to WIM-301 and WIM-302, an analog input module (NI 9205) that will connect to WIM-303, and an analog output module (NI 9264) that will connect to WIM-304. The NI 9403 is a 32-channel, TTL DIO module, the NI 9205 is a 32channel, ±10 V, 16-bit analog input module, and the NI 9264 is a 16-channel, ±10 V, 16-bit analog voltage
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output module.
We chose 16-bit modules because of the finely-grained control they would enable us to have over the ride. The voltage range is 20 V, so we can control the ride in
𝑟𝑎𝑛𝑔𝑒 20 𝑉 = 16 = 0.305 𝑚𝑉 𝑠𝑡𝑒𝑝𝑠 2𝑛−𝑏𝑖𝑡 2
( 1)
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𝑞𝑢𝑎𝑛𝑡𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑠𝑡𝑒𝑝𝑠 =
in each degree of freedom (DOF), which is an especially good hedge if the actuators do not have a linear response.
The CRIO takes an input of 9-30 V to turn it on, so we wired the CRIO to the +24 V PS on the distribution panel, as shown below:
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W n by e nc rre Te Figure 23. +24 V PS
We chose this power supply because it had a set of unoccupied output terminals. The +24 V output is well within the range needed by the CRIO.
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After some testing of the CRIO, we realized we could connect it to the network switch on the distribution panel.
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The switch had been used to connect the motion PC to a (now) removed gaming PC. The motion PC has a
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static IP address, 10.10.101.90. We normally connected to the motion PC by changing the properties of the network of the ride’s new gaming PC, but we received a router,
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Figure 25. Netgear Router
so we were able to set up DHCP reservations on the 10.10.101.* network. The IP address for the router is 10.10.101.1, the CRIO, 10.10.101.2, the motion PC, 10.10.101.90, and the gaming PC, 10.10.101.94. The
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router’s DCHP reservations forces items connected to it with a certain MAC address to use a given IP. It also makes it easier to add anything else to this network later.
Before the CRIO was installed on the simulator’s network, we installed the LabView Professional Development System on the gaming PC to set up the CRIO. The ECE department provided The Drexel Ride
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gaming PC with a license key for LabView, the FPGA Module, the Control Design and Simulation Module, and Xilinx Tools 14.4. With the full LabView suite of programs, we were able to design and test programs
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Our first step was to connect it to the analog input, WIM-303. We connected the pitch, roll, and
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lift terminals to the CRIO to observe how they varied while the ride was running. A test program was created to see how they varied:
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Figure 26. LabView Test Program
When the ride is not running, the sensor voltages are about 5.5 V for the roll, and about 1 V for the pitch
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and lift. When the ride is running, all of the sensors vary according to their positions.
