After the exhaustive mapping of the distribution panel last quarter, our first task this quarter was to wire the cRIO to the distribution panel in place of the motion computer. We bought 50-pin ribbon cable,
the ribbon cables, we plugged them into the breakout boards.
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50-pin IDC socket connectors, a crimper, and four 50-pin breakout boards. After we cut and assembled
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Te Figure 1. 50-pin Ribbon Cables, Breakout Boards, and Wires
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We used one breakout board per WIM, which gave us access to the channels on the WIMs needed to control the ride. The pins for these channels were connected to the cRIO with wires shown in the above
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figure. The wires connected to the cRIO’s modules through a NI 9923, a screw terminal to 37-pin DSUB
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connector block.
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Figure 2. NI 9923
Three of the modules required a NI 9923; the analog output module connected to the breakout board
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directly.
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Figure 3. cRIO Module Connections
The next task was to turn on the hydraulic motor. Observation of the startup of the old motion computer
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demonstrated that the two relays controlling the hydraulic motor were the MC E-STOP (emergency stop) and WDT (watchdog timer) relays.
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Figure 4. Six Relays to Control the Ride
The MC E-STOP relay controls the application of +24 V (from the +24-volt power supply) to all the safety
down or freezes, the WDT output goes to zero, which turns off the WDT relay, and consequently the
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sensors on the ride, and the WDT makes sure the computer is running properly. If the computer slows
hydraulics.
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Te Figure 5. Watchdog Timer (WDT) and associated relay
timer requires three inputs for an output: a high
and a square wave with a frequency of about one
Figure 6. Timing Diagram from Datasheet
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Hertz on the “A” terminal.
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on the “+” terminal, a low on the “-“ terminal,
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and the datasheet for the timer revealed that the
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Studying both the provided schematics
The MC E-STOP relay was another challenge. The RR2P-UL DC24V relay used on the distribution panel requires 60 mA at 24 V, but at 5 volts (“1”, a digital high) it requires about 250 mA. The NI 9403 DIO
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modules can only source current maximum of 2 mA, so a method of activating the relays was necessitated. Another, smaller relay was used. A 5-volt, SPST relay was used to step the DIO’s output up to 24 V.
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up the DIO’s output to 24 V for the blocking, lift, roll, and pitch relays.
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Figure 7. Coto Technology SPST 5V Relay
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The outputs from the relays were sent through the breakout board to the channel that controlled the associated RR2P-UL DC24V relay. The relays were mounted on a breadboard next to the breakout
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board connected to WIM-301.
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The cRIO and the breakout boards were mounted on plywood under the motion computer.
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Figure 9. cRIO mounted under Motion PC
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Each breakout board is used to pass signals between the cRIO modules and its respective WIM. WIM301’s breakout board is shown in the figure below, and its connections are listed in the table below:
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Figure 11. WIM-301's Breakout Board Table 1. Signals on WIM-301
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BRK2x25 Cable 9923 9403 1 white 7 6 3 orange 8 7 7 red 11 8 9 brown 12 9 DIO 11 blue 13 10 13 yellow 14 11 15 white 26 22 8 green 9 COM
INPUTS OUTPUTS
20 22 25 28 31 34 37 18
20 22 25 28 31 34 37 18
orange red
27
brown blue
31
23
green
30
DIO
24 25
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6 5 4 3 2 1 0
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MC E-STOP OUTPUT door open enable door close enable blocking enable lift enable roll enable pitch enable ground
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Channel WIM-301 oil temperature ok 7 1 gondola ride pushbutton 6 3 right seat belt locked 4 7 left seat belt locked 3 9 e-stop line 2 11 tape switch ok 1 13 door closed 0 15 ground 8
32
26
10
COM
This is the most important WIM because all of the safety signals pass through it, and all of the control
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relays are activated through it.
WIM-302’s breakout board is shown in the figure to the right, and its connections are listed
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in the table below:
Figure 12. WIM-302's Breakout Board
Table 2. Signals on WIM-302
20 25 28 34 37 8
27 30 31 32 33 10
orange 23 red 24 brown 25 DIO blue 26 yellow 27 green COM
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20 25 28 34 37 18
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6 4 3 1 0
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E-STOP reset light restraints ok light door closed light run button light home button light ground
BRK2x25 9923 Cable 9403 1 7 white 6 3 8 orange 7 5 11 red 8 7 12 brown 9 9 13 blue 10 13 14 yellow DIO 11 15 26 white 22 8 9 green COM 39 3 red 2 40 4 brown 3 50 28 green COM
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OUTPUTS
WIM-302 1 3 5 7 9 13 15 8 wim-304 pin 39 wim-304 pin 40 wim-304 pin 50
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INPUTS
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Channel 7 close door switch 6 e-stop reset button 5 e-stop button 4 run button 3 home button 1 demo mode selected 0 normal mode selected ground 0 WDT+ watchdog timer WDT-
WIM-302 is not currently being used because the control panel has been bypassed.
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WIM-303’s breakout board is shown in the figure to the right, and its connections are listed
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in the table below:
Figure 13. WIM-303's Breakout Board
BRK2x25 9923 9205 2 1 AI0 4 2 AI1 6 3 AI2 7 10 COM
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WIM-303 2 4 6 7
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Table 3. Signals on WIM-303
WIM-303 carries the positional voltages of the actuators.
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WIM-304’s breakout board is shown in the figure to the right, and its connections are listed
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in the table below:
Figure 14. WIM-304's Breakout Board
BRK2x25 9264 2 AO1 3 AO2 4 AO3 5 AO4 6 AO5 7 AO6
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WIM-304 2 3 4 5 6 7
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Table 4. Signals on WIM-304
WIM-304 passes the voltages from the analog output module to move the ride in each DOF, and the three
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inputs to the watchdog timer connects on the left side of the WIM.
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After wiring the cRIO to the distribution panel through the WIMs, we created a LabVIEW program that would enable us to control the ride. Shown below is the program.
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The buttons on the left side of the program turn on all the control relays and get the ride ready to receive
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inputs from the drive commands. On the bottom left of the program, the positional voltages from the
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actuators are shown. The drive commands are on the bottom right of the program. Entering a number in one these boxes applies a differential voltage to the respective DOF, and move the actuator. Changing the
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number back to zero stops the actuator from moving. A higher number moves the ride faster; the numbers
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in the box are limited by the output of the analog output module, ±10 V.
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