Low-Cost Multiple Sensor Inertial Measurement System For .

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High-Speed Rail IDEA ProgramLow-Cost Multiple Sensor Inertial Measurement Systemfor Locomotive NavigationFinal Report for High-Speed Rail IDEA Project HSR-14Prepared by:Fred Riewe, Principal InvestigatorENSCO, Inc.July 1996

INNOVATIONS DESERVING EXPLORATORY ANALYSIS (IDEA) PROGRAMS MANAGED BY THETRANSPORTATION RESEARCH BOARDThis investigation was performed as part of the High-Speed Rail IDEA program supports innovativemethods and technology in support of the Federal Railroad Administration’s (FRA) next-generationhigh-speed rail technology development program.The High-Speed Rail IDEA program is one of four IDEA programs managed by TRB. The other IDEA programs arelisted below. NCHRP Highway IDEA focuses on advances in the design, construction, safety, and maintenance of highwaysystems, is part of the National Cooperative Highway Research Program.Transit IDEA focuses on development and testing of innovative concepts and methods for improving transitpractice. The Transit IDEA Program is part of the Transit Cooperative Research Program, a cooperative effort of theFederal Transit Administration (FTA), the Transportation Research Board (TRB) and the Transit DevelopmentCorporation, a nonprofit educational and research organization of the American Public Transportation Association.The program is funded by the FTA and is managed by TRB.Safety IDEA focuses on innovative approaches to improving motor carrier, railroad, and highway safety. Theprogram is supported by the Federal Motor Carrier Safety Administration and the FRA.Management of the four IDEA programs is integrated to promote the development and testing of nontraditional andinnovative concepts, methods, and technologies for surface transportation.For information on the IDEA programs, contact the IDEA programs office by telephone (202-334-3310); by fax (202334-3471); or on the Internet at http://www.nationalacademies.org/trb/ideaIDEA ProgramsTransportation Research Board500 Fifth Street, NWWashington, DC 20001The project that is the subject of this contractor-authored report was a part of the Innovations DeservingExploratory Analysis (IDEA) Programs, which are managed by the Transportation Research Board (TRB)with the approval of the Governing Board of the National Research Council. The members of the oversightcommittee that monitored the project and reviewed the report were chosen for their special competencies andwith regard for appropriate balance. The views expressed in this report are those of the contractor whoconducted the investigation documented in this report and do not necessarily reflect those of theTransportation Research Board, the National Research Council, or the sponsors of the IDEA Programs. Thisdocument has not been edited by TRB.The Transportation Research Board of the National Academies, the National Research Council, and theorganizations that sponsor the IDEA Programs do not endorse products or manufacturers. Trade ormanufacturers' names appear herein solely because they are considered essential to the object of theinvestigation.ii

Low-Cost Multiple Sensor Inertial Measurement Systemfor Locomotive NavigationIDEA Program Final Reportfor the Period July 1998 Through October 1999IDEA HSR-14Prepared forthe IDEA ProgramTransportation Research BoardNational Research CouncilFred Riewe, Principal InvestigatorENSCO, Inc.Aerospace Sciences and Engineering Division1980 North Atlantic Ave., Suite 230Cocoa Beach, Florida 329311 March 2000iii

Table of Contents1.2.3.4.5.6.7.8.9.EXECUTIVE SUMMARY .1IDEA PRODUCT.32.1 PRODUCT DESCRIPTION .32.2 SYSTEM REQUIREMENTS AND ARCHITECTURE .42.2.1 Processing State Requirements.42.2.2 Algorithm Requirements .42.2.3 Performance Requirements.52.2.4 Accuracy Requirements.5CONCEPT AND INNOVATION.53.1 MEMS AND OTHER INEXPENSIVE SENSORS.63.1.1 Accelerometers .63.1.2 Gyros .73.2 MULTIPLE SENSORS.83.3 Combining Sensors with Different Characteristics .83.3.1 Using Accelerometers as Gyros.93.3.2 Advantages of Multiple Sensors.11INVESTIGATION .114.1 ALGORITHMS.114.1.1 Filter Algorithms .114.1.2 Sensor Algorithms .124.1.3 System Software .124.2 SENSORS .134.3 SIMULATIONS.134.4 LABORATORY TESTING.144.4.1 Laboratory Equipment .144.4.2 Laboratory Evaluation System.144.5 FIELD TEST.174.6 DATA EVALUATION.184.6.1 Switching Between Parallel Tracks .184.6.2 Extension of Analysis to Lower Speeds .224.6.3 Overall Accuracy of Future Inertial Navigation Systems Based on Present Analysis .234.7 PRESENTATIONS AND COMMUNICATION .244.7.1 Panel of Advisors.244.7.2 Oversight Committee Presentation .244.7.3 Seminars on Kalman Filtering, Navigation, and Digital Signal Processing .244.7.4 Documentation.25PLANS FOR IMPLEMENTATION.255.1 DESIGN OF COMMERCIAL SYSTEM .255.1.1 Sensors.275.1.2 Computer .275.1.3 Software.275.1.4 Electronics .285.1.5 Packaging .285.1.6 Costs .295.1.7 Testing and Quality Assurance.295.2 COMMERCIALIZATION.29CONCLUSIONS .31INVESTIGATOR PROFILE .317.1 PRINCIPAL INVESTIGATOR.317.2 OTHER KEY PERSONNEL .32ACRONYM LIST .33REFERENCES.33iv

1. EXECUTIVE SUMMARYAdvanced train control systems suchas Positive Train Separation (PTS) andPositive Train Control (PTC) requireknowledge of the location of a locomotivealong the track. They must also be able todetect when the locomotive transfers to aparallel track. This project successfullydemonstrated that it is possible to design alow-cost Inertial Navigation System (INS)capable of detecting track switching. Theimportance (and complexity) of detectingmovement to an adjoining track isillustrated by Figure 1. The project alsodeveloped algorithms and software for datafiltering and navigation for use in thedevelopment of a future INS product.Figure 1. Locomotive navigation systems must not onlydetermine location along a track, but must also detectmovement onto a parallel track. (Photo taken during ENSCOIDEA field testing.)The present project field tested adistributed array of sensors suitable forproviding data to an INS. This MultipleSensor Inertial Measurement System (MSIMS) uses inexpensive MicroElectroMechanical Systems (MEMS)accelerometers (Figure 2), which are configured to provide both linear and rotational data, eliminating the need forexpensive gyros. Analysis of the field test data from a rail car demonstrated that it is practical to detect switching toa parallel track using the MSIMS. For future applications, navigation along the track can be performed using thesame MSIMS, extended to use Global Positioning System (GPS) or Differential GPS (DGPS) data along withnavigation and Kalman filtering software. An Inertial Measurement System (IMS) extended in this way becomes anInertial Navigation System (INS), capable of providing complete navigation information. This project did notrequire development of navigation or GPS-integration software. However, ENSCO did independently design andimplement full navigation and GPS-aided Kalman filtering for thesystem. The navigation software development is complete and ispresently being checked out and optimized. It will be available forapplication in a future commercial INS product based on thepresent project.Figure 2. Microphotograph of aMEMS accelerometer, shown next tothe three-axis module used for fieldtesting. The accelerometer chip is 0.11inches square and the module is1x1x0.75 inches.The development of the MSIMS began with a requirementsdefinition phase, in which the system, algorithm, performance, andaccuracy requirements, and initial system architecture weredetermined. The requirements are based on the need to support PTSand PTC applications. These requirements and specifications havebeen compiled in two documents, the System Specification for theMultiple Sensor Inertial Measurement System for LocomotiveNavigation and the Algorithm and Performance Requirements forthe Multiple Sensor Inertial Measurement System for LocomotiveNavigation.Early in the project, we evaluated technology options forsensors appropriate to the application. We found that the type of Analog Devices, Inc. accelerometers identified inthe proposal remained the best choice. For the initial proof-of-concept MSIMS, we used Analog DevicesAccelerometer Evaluation Modules, Model ADXL150EM-3. We also developed a laboratory evaluation systemusing individual ADXL150 and ADXL250 accelerometers. In order to record rotational data for algorithm testing,we incorporated three Murata Gyrostar ENV-05D micromachined gyros. We used a 12-bit data acquisition systemto record data from the laboratory system for evaluation of the sensors and to provide data for testing and evaluatingour sensor, navigation, and Kalman filtering algorithms. LabTech Notebook software was used to simultaneouslyrecord inertial data and GPS receiver output. We recorded data on a number of vehicles, including rail cars,automobiles, a van, and an elevator.1

We evaluated methods of using multiple accelerometers to increase accuracy. By combining sensors ofdifferent resolutions and ranges, the resulting output is superior to that of a single sensor. For example, if a sensorlocation aboard a locomotive experiences low accelerations at most times, with infrequent short occurrences of highacceleration, then a wide-range sensor and a high-resolution sensor can be used in combination to provide a widerange of measurement, while not sacrificing accuracy at most accelerations encountered by the application. We havesimulated the effect of combining sensor data and found a significant improvement over single-sensor data. Theeffect was also measured under static conditions using the laboratory evaluation system. All sensors used for fieldtesting had the same range, so this effect could not be analyzed using the field test data.We have developed algorithms for determining acceleration and angular velocity from arrays of accelerometers.We simulated the accuracy of rotational measurements obtained from pairs of accelerometers. We also calculatedthe accelerations expected from a locomotive switching between two parallel tracks. We then performed simulationsthat showed the accuracy required for a system of multiple accelerometers to measure acceleration and angularvelocity under a variety of conditions. We next evaluated various configurations of accelerometers and three-axisaccelerometer modules and determined an appropriate configuration for the MSIMS to be used for field testing.The field test of the MSIMS sensor arraywas conducted on 3 August 1999 using theAmtrak 10002 High-Speed Track Geometry Car,seen in Figure 3. The test consisted of datarecording for future analysis using four sets ofthree-axis MEMS accelerometers, mounted in thecorners of the car. The Laboratory EvaluationSystem was mounted in a central location andreference accelerometers were placed at the endsand center of the car. The total data-recordingtime was approximately 6 hours. The recordeddata will be available for future verification ofthe filtering and navigation software and aportion of the data was analyzed to demonstratethe ability to detect track switching.Figure 3. Recording data during field test on AmtrakAnalysis of a segment of the field-test data10002 High-Speed Track Geometry Car.recorded at 30 mph demonstrated that it ispossible to detect switching to a parallel track.Further analysis indicated that the tested sensors should be capable of determining the route taken at a turnout at 10mph or lower. Newly available AXDL105 MEMS accelerometers from Analog Devices, Inc. have five times theresolution of the tested sensors, indicating that positive detection may be possible at speeds of 1-2 mph.This project produced the following significant findings: low-cost MEMS accelerometers are practical for replacing more expensive single accelerometers, simulations showed that combining sensors with multiple ranges can provide increased accuracy, pairs of accelerometers can be used to measure angular velocity, and use of a long baseline to separate accelerometers improves accuracy of rotational measurements.The MSIMS developed by this project differs in two areas from conventional inertial systems. The system uses an array of inexpensive sensors to replace more expensive single sensors. The design also reduces cost by using accelerometers separated by a long baseline to replace expensive gyros.We have designed an MSIMS inertial navigation product and have submitted an IDEA Type 2 proposal to build aprototype system: Low Cost Multiple Sensor Inertial Measurement Product for Locomotive Navigation. TheMSIMS product will have the following advantages over conventional navigation systems: has low cost (initially 2-3000 per unit, depending on configuration), has small size, due to use of MEMS accelerometers, takes advantage of specialized rail data, including wheel tachometer, transponders, and turnout detection, is optimized for railroad applications by making use of one-dimensional nature of railroad track, is specifically designed for detecting switching between parallel tracks, uses multiple sensors to provide redundancy in case of sensor failure, and uses the inertial sensor technology (MEMS) expected to become dominant in the future.2

2. IDEA PRODUCT2.1 PRODUCT DESCRIPTIONThe Federal Railroad Administration (FRA) is involved in demonstration projects of advanced train controlsystems that include a locomotive navigation function. These projects have used conventional rate gyros and laserfiber optic gyros for rate sensors. The technology we have explored in this project has the potential to greatly reducethe cost of locomotive navigation systems while meeting the accuracy requirements of Positive Train Separation(PTS) and Positive Train Control (PTC) systems. Accuracy requirements have specified locatio

low-cost Inertial Navigation System (INS) capable of detecting track switching. The importance (and complexity) of detecting movement to an adjoining track is illustrated by Figure 1. The project also developed algorithms and software for data filtering and navigation for use in the development of a future INS product.

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