Intelligent Train Engines( Click here to book this project)

We know that the railway network of India is the biggest in south Asia and perhaps the most
complicated in all over the world. There are so many different types of trains local, fast, super
fast, passenger, goods…. etc. and their so many multiple routs. Although the time table is perfect
it is not at all possible to maintain it. And that’s why the train accidents are becoming more and
more usual. So why not we add a kind of intelligence to the train engines itself so that it tries to
avoid accidents.

The idea is whenever any engine observes a red signal on its track it will start decreasing its
speed gradually and stops automatically at some distance from the signal pole. After then when it
gets green signal the driver can manually start the train and go on. In the mean time when train
has not stopped yet and a red signal becomes green then it crosses the signal pole with low speed
and then driver can slowly increase the speed.

So now before the driver observes the red signal the engine itself observes it and automatically
starts decreasing speed and then stops. The driver can feel relax in driving because he doesn’t
have to take care about red signal. Even if he forgets to take any action on red signal then also
we can avoid accidents by the implementation of this idea.

General description:

What we have to do is we have to attach a transmitter with signal pole which will start
transmitting signals only when the red light is on. If there is green light no transmission. The
engine has a receiver which catches these transmitted signals and takes desire actions.

Both the transmitter and receiver are of RF type with minimum range of 2 Km. so that train can
get enough time to decrease its speed and stop before the signal pole with minimum swapping
distance of 100-200 mt.

Here in our project we have used IR transmitter and receiver instead of RF for demo purpose.
But same idea can be easily implemented with RF also with a little more cost.

Lets first discuss the demonstration model.

Demonstration Model:

The train engine runs on 24V DC motor so that we can easily vary its speed by varying applied
voltage. The switching voltage is applied in step of 18 V, 15 V, 12 V and 9 V (min speed). The
230 VAC is step-down to 24 VAC by 12-0-12, 2 Ampere step down transformer. As shown in
figure this 24 VAC line runs parallel with track at the top of the train. Movable tapping are taken
from this line and fed to the internal circuit of engine. These tapping slides as the train runs on
the track and give continuous supply to circuit. The IR sensor is placed at the top of the engine,
senses the signals transmitted by IR transmitter attached to signal pole. Train track is straight and
20 ft long. Signal pole is placed at the end of track and train starts from farther end.

Model of Intelligent Train Engines

The project is divided in two parts

Transmitter
Receiver

The transmitter is housed in signal pole and it is activated only when red light is ON.

The receiver is housed in engine which senses the IR signals and takes suitable action.

Signal Pole IR Transmitter:-

The
figure shows the schematic diagram of IR transmitter.

Schematic diagram of IR transmitter.

The heart of the circuit is IC555. The main component of the circuit is only IC555.

Connections:
Both ICs are connected in astable mode. The frequency of U2 is 0.5 Hz and U1 is 38 KHz. This
is decided by RC components connected with it. The output of U2 is connected with reset pin (4)
of U1. Thus the output of U2 controls the operation of U1 means it will switch on or off the
output of U1. The output of U1 is fed to two IR LEDs through Darlington pair made up of Q1,
Q2 and R5. The 9V DC battery is connected with circuit through SPDT switch SW1 as shown.

Operation:

As shown in figure when SW1 is in position as shown the transmitter is On and also the red LED
is also ON. When switch changes its position the red LED and transmitter is off and only green
LED will on. When the circuit is energized U2 will start generating high pulse at every 1 sec. as
this pulse is fed to reset pin of U1 it will generate 38 KHz square wave and give it to IR leds. IR
leds will generate IR beam of 38 KHz for the same time. Thus after every one second the IR
beam of 38 KHz is generated for one second only. This cycle repeats till the red light is on.

Note: The range of this transmitter is limited to 10 ft only.

89C51 based IR receiver for Engine:

The IR receiver circuit housed in engine is as shown below.

IR receiver circuit

The main components of the circuit are IR sensor TSOP 1738, microcontroller 89C51, current
driver chip ULN2003A and all voltage regulator ICs (78XX series).
Connections:
24 VAC is rectified by diode bridge D1 and filtered through C1 and given to all the regulated ICs
as input.
The output of 7805 is connected to 89C51 and TSOP and also to all the LEDs.
Output of 7812 (last one) is connected to common coil terminal and to ULN
The outputs of middle four regulated ICs are connected to DC motor through relay contacts.
Output of TSOP is connected with pin P3.3 (INT1) of microcontroller
All five leds are connected with port P0 as shown
Input of ULN is connected with Port 1 pins P1.0-P1.3, and outputs are connected with second
terminal of relay coil.

Operation:
TSOP will detect the 38 KHz IR beam and gives the interrupt to 89C51.
89C51 will indicate the interrupt event on first (green) LED and energizes only one particular
relay through ULN chip.
When any of the four relay get energized the motor will get supply from it and it will start
running
As voltage is less it will run with less speed
So now its the function of microcontroller to receive signal from IR sensor, decrease the speed of
train gradually in four steps and then stop it. And this is done by software embedded in to 89C51.

How the project works?

Initially when you switch on the supply 89C51 will switch all the relays RL1- RL4 one by one.
So motor will get 9-12-15-18 V supply in steps and gradually increases its speed reaches max
speed indicated by first red LED (P0.0).
Now if the signal is green then train will cross the pole with same pole
But if signal becomes red in between then IR sensor will detect IR beam and interrupts the
89C51
Getting first interrupt 89C51 will switch off RL4 and switch on RL3 so now motor will get 15 V
supply and its speed will be decreased. That’s indicated by second red LED (P0.1)
Now 89C51 will wait for some time (2 to 3 sec) and train goes on with same speed. Again if still
red signal is on 89C51 will be interrupted and this time it will switch on RL2. so now motor gets
12V supply and again its speed will be decreased indicated by third red LED (P0.2)
The same procedure repeats if 89C51 is interrupted third times. Now motor runs at min speed (9
V) indicated by fourth red LED (P0.3)
After same delay on receiving fourth interrupt all the relays will be switched off and motor is
now stop so the train is also stopped. This is indicated by green LED.
After this interrupts will be disabled. So now when red signal becomes green driver must reset
the controller to start the train again.

The complete pseudo code with necessary comments is as given

org 00h
mov r0,#01h ; initialize the counter to count no. of interrupts
sjmp over ; jump above the interrupt subroutine
org 0013h ; interrupt 1 subroutine location
mov ie,#00h ; disable interrupt first
clr p0.0 ; interrupt indication on green led
inc r0 ; increment counter
acall delay ; call 0.1 sec delay
setb p0.0 ; reset green led
cjne r0,#02h,nxt2 ;if counter is 2 then decrease speed be one step (15 V)
mov p0,#0fbh
mov p1,#04h ; give indication on second red led
sjmp out
nxt2: cjne r0,#03h,nxt3 ; if counter is 3 then decrease speed be two step (12 V)
mov p0,#0f7h
mov p1,#02h ; give indication on third red led
sjmp out
nxt3: cjne r0,#04h,nxt4 ; if counter is 4 then decrease speed be three step (9 V)
mov p0,#0efh
mov p1,#01h ; give indication on fourth red led
sjmp out
nxt4: cjne r0,#05h,out ; if counter is 5 then stop the train
mov p0,#0feh
mov p1,#00h ; indicate it by green led.
out: acall dely ; call 2 sec delay every time when speed is changed
mov ie,#84h ; enable interrupt again
reti ; return from interrupt
over:mov p1,#01h ; main program starts from here starts train with min speed
acall dely ; and gradually increase it to max in four step
mov p1,#02h ; with 2 sec delay in between
acall dely
mov p1,#04h
acall dely
mov p1,#08h
mov p0,#0fdh
mov ie,#84h ; enable the interrupt
here: sjmp here ; continue loop
delay:
mov r6,#64h ; 0.1 sec delay
lop2:mov r5,#0FAh
lop1:nop
nop
djnz r5,lop1
djnz r6,lop2
ret
dely:
mov r7,#15h ; 2 sec delay
lop5:mov r6,#64h
lop4:mov r5,#0FAh
lop3:nop
nop
djnz r5,lop3
djnz r6,lop4
djnz r7,lop5
ret
end

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August 3, 2009 Posted by Common wealth games | project ideas | 30 Comments

Line Robot
 

Line Robot
Recently
many kind of robot contests have being opened and some interesting reports of
the challenge are found on the web. The Line Following is a kind of the robot
contests to vie running speed on the line. I build a tiny line following robot
which can run on the desk, moving the key board aside will do. It is for only
a personal toy reduced its size less than one fifth compared to typical line
following robots, not in formura. But I believe that it is suitable for home
use in the small Japanese houses said that rabbit burrow…(^_^;. Of course
I have also no time to take part in the robot contests

About Line Follower

The line follower is one of the self operating robot that follows a line
that drawn on the floor. The basic operations of the line following are as follows:

1. Capture line position with optical sensors mounted at front end of the
robot. Most are using several number of photo-reflectors, and some leading
contestants are using an image sensor for image processing. The line sensing
procss requires high resolution and high robustness.
2. Steear robot to track the line with any steearing mechanism. This is
just a servo operation, any phase compensation will be required to stabilize
tracking motion by applying digital PID filter or any other servo argolithm.
 3. Control speed according to the lane condition. Running speed is limited
during passing a curve due to friction of the tire and the floor.

There are two line styles, white line on the black floor and black line on
the white floor. Most contest are adopting the first one in line width of between
15 and 25 millimeters.

Hardware

Mechanics

Right image shows bottom view and side view of the built line following robot.
All mechanical and electrical parts are mounted on a proto board, and it also
constitutes the chasis.

The line following robot is upheld in three points of two driving wheels
and a free wheel. The driving wheels are made with a 7 mm dia ball bearing and
a rubber tire. The free wheel is a 5 mm dia ball bearing attached loosely. To
drive driving wheels, two tiny
vibration motors that used
for cellular phone, pager or any mobile equipment are used. Its shaft is pressed
onto the tire with a spring plate, the output torque is transferred to the wheels.

The steearing mechanism is realized in differential drive that steear

the robot by difference in rotation speed between the left wheel and the right
wheel. It does not require any additional actuator, only controling the wheel
speed will do.

Electronics

Controller ATmega8 (Atmel)

Line sensor Six photo-reflectors
Two CR2032 lithium cells
Power supply
(One is for controller, the other is for motors)
Two micromotors for
Motor
left wheel and right wheel
45(L), 33(W), 12.5(H)
Dimensions
[mm]
15 grams (Body:8g,
Weight
Cells:7g)
 53 centimeter per second
Performance
at oval course

An Atmel ATmega8 is used for the controller and it is powered by a lithium

coin cell. The other lithium coin cell is for only motors. Separating the power
supply into two cells is to avoid accidental reset of the microcontroller due
to voltage dip by motor start current. Six photo-reflectors are mounted at front
end of the chasis. They sense reflection rate of the floor under them. Motors
are driven in PWM to control rotation speed lineary. The latest circuit diagram
is here.

Software

Using photo-reflectors

To detect a line to be followed, most contestants are using two or more number
of poto-reflectors. Its output current that proportional to reflection rate
of the floor is converted to voltage with a resister and tested it if the line
is detected or not. However the threshold voltage cannot be fixed to any level
because optical current by ambent light is added to the output current like
the image shown right.
Most photo-detecting modules for industrial use are using modurated light
to avoid interference by the ambient light. The detected signal is filtered
with a band pass filter and disused signals are filtered out. Therefore only
the modurated signal from the light emitter can be detected. Of course the detector
must not be saturated by ambient light, this is effective when the detector
is working in linear region.

In this project, pulsed light is used to cancel ambient light. This is suitable
for arraied sensors that scanned in sequence to avoid interference from next
sensor. The microcontroller starts to scan the sensor status, sample an output
voltage, turn on LED and sample again the output voltage. The difference between
the two samples is the optical current by LED, output voltage by the ambient
light is canceled. The other sensors are also scanned the same avobe in sequence.

Signal processing of line detection

Right image shows the actual line posisiton vs detected line position in
center value of 640. The microcontroller scans six sensors and calcurates the
line position by output ratio of two sensors near the line. Thus the line position
can be detected lineary with only six sensors. All the sensor outputs are captured
as analog value that proportioning to reflection ratio, and the sensitivity
have variety between each one of them. In this system, to remove the variations
from the outputs, calibration parameters for each sensor can be held into non-volatile
memory. This can be done with online mode. The microcontroler enters the online
mode when an ISP
cable is attached, and it can be controlled with a terminal program in serial
format of N81 38.4kbps. S1 command monitors sensor values, and S2 command calibrates
variation of sensor gain on the reference surface (white paper). The ATmega8
must be set to 8MHz internal osc.
Tracking control

The line position is compeared to the center value to be tracked, the position
error is processed with Proportional/Integral/Diffence filters to generate steering
command. The line folloing robot tracks the line in PID control that the most
popular argolithm for servo control.

The proportional term is the commom process in the servo system. It is only
a gain amplifire without time dependent process. The differencial term is applied
in order to improve the responce to disturbance, and it also compensate phase
lag at the controled object. The D term will be required in most case to stabilize
tracking motion. The I term is not used in this project from following resons.
The I term that boosts DC gain is applied in order to remove left offset error,
however, it often decrease servo stability due to its phase lag. The line following
operation can ignore such tracking offset so that the I term is not required.

When any line sensing error has occured for a time due to getting out of
line or end of line, the motors are stopped and the microcontroller enters sleep
state of zero power consumption.

Notes
  Development diary [Ja]
 Circuit diagram
 Firmware May 23, 2004
 Following motion
with only P control
This is a video file of line following motion with only P control. The servo
system oscllated.
 Following motion
with P and D controls
Adding D control could improve the servo stability. The robot follows the
line correctly. Therefore the servo parameter must be optimized for mechanical
characterristics to improve the tracking stability.

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December 18, 2008 Posted by Common wealth games | project ideas | 11 Comments

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