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Onboard Monitoring and Control – Wireless Sensor Networks Systems Integration DTFR53-12-D-00003L 6 U.S. Department of Transportation Onboard Monitoring and Control – Wireless Federal Railroad Sensor Networks Systems Integration Administration Office of Research, Development, and Technology Washington, DC 20590 DOT/FRA/ORD-21/21 Final Report July 2021 NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Government assumes no liability for its contents or use thereof. NOTICE The United States Government does not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the objective of this report. REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. 1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED July 2021 Technical Report 4. TITLE AND SUBTITLE 5. FUNDING NUMBERS Onboard Monitoring and Control – Wireless Sensor Networks Systems Integration DTFR53-12-D-00003L 6. AUTHOR(S) Task Order 0011 Tom Campbell*, Dr. Hamid Sharif** 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION *QinetiQ North America **University of Nebraska – Lincoln REPORT NUMBER 350 Second Avenue Telecommunications Engineering Laboratory Waltham, MA 02451-1196 1110 S 67th Street Omaha, NE 68182 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/MONITORING U.S. Department of Transportation Federal Railroad Administration AGENCY REPORT NUMBER Office of Research, Development, and Technology DOT/FRA/ORD-21/21 Washington, DC 20590 11. SUPPLEMENTARY NOTES COR: Tarek Omar, Ph.D. 12a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE This document is available to the public through the FRA website. 13. ABSTRACT (Maximum 200 words) A practical wireless train network (WTN) for freight trains is defined. A hybrid technology network utilizing ZigBee within each railcar and WiFi to create an ad hoc train network is researched. Motes and PAN-coordinators have been fabricated for demonstration testing. Network software were developed and embedded for testing. A specialized wheel bearing sensor was developed; it contains a thermistor, a 3-axis accelerometer, and a microphone. The sensor components were fabricated and the firmware has been developed. Raw data can be acquired or the fast Fourier transforms can be compared to thresholds for alerts. A demonstration was designed and built to activate and deactivate electronically deployed hand brakes developed by Sharma and Associates. This can enable the activation of hand brakes remotely from the locomotive for every railcar. The WTN was developed to self-initiate as the train leaves the departure yard. Activation is based on the attachment of the End-of-Train device and forward acceleration in each railcar. WiFi beacons from the gateway are detected by each railcar in series as they accelerate forward. That timing determines the railcar order. Direction of forward accelerations determines the railcar orientation. The data are automatically assembled as the train departs and is uploaded to the enterprise. 14. SUBJECT TERMS 15. NUMBER OF PAGES Wireless train network, hybrid technology network, wheel bearing sensor, train health 70 monitoring, wireless sensor network, ad hoc network, freight train network 16. PRICE CODE 17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT OF REPORT OF THIS PAGE OF ABSTRACT Unlimited Unclassified Unclassified Unclassified NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89) Prescribed by ANSI Std. 239-18; 298-102 iii METRIC/ENGLISH CONVERSION FACTORS ENGLISH TO METRIC METRIC TO ENGLISH LENGTH (APPROXIMATE) LENGTH (APPROXIMATE) 1 inch (in) = 2.5 centimeters (cm) 1 millimeter (mm) = 0.04 inch (in) 1 foot (ft) = 30 centimeters (cm) 1 centimeter (cm) = 0.4 inch (in) 1 yard (yd) = 0.9 meter (m) 1 meter (m) = 3.3 feet (ft) 1 mile (mi) = 1.6 kilometers (km) 1 meter (m) = 1.1 yards (yd) 1 kilometer (km) = 0.6 mile (mi) AREA (APPROXIMATE) AREA (APPROXIMATE) 1 square inch (sq in, in2) = 6.5 square centimeters (cm2) 1 square centimeter (cm2) = 0.16 square inch (sq in, in2) 1 square foot (sq ft, ft2) = 0.09 square meter (m2) 1 square meter (m2) = 1.2 square yards (sq yd, yd2) 1 square yard (sq yd, yd2) = 0.8 square meter (m2) 1 square kilometer (km2) = 0.4 square mile (sq mi, mi2) 1 square mile (sq mi, mi2) = 2.6 square kilometers (km2) 10,000 square meters (m2) = 1 hectare (ha) = 2.5 acres 1 acre = 0.4 hectare (he) = 4,000 square meters (m2) MASS - WEIGHT (APPROXIMATE) MASS - WEIGHT (APPROXIMATE) 1 ounce (oz) = 28 grams (gm) 1 gram (gm) = 0.036 ounce (oz) 1 pound (lb) = 0.45 kilogram (kg) 1 kilogram (kg) = 2.2 pounds (lb) 1 short ton = 2,000 pounds = 0.9 tonne (t) 1 tonne (t) = 1,000 kilograms (kg) (lb) = 1.1 short tons VOLUME (APPROXIMATE) VOLUME (APPROXIMATE) 1 teaspoon (tsp) = 5 milliliters (ml) 1 milliliter (ml) = 0.03 fluid ounce (fl oz) 1 tablespoon (tbsp) = 15 milliliters (ml) 1 liter (l) = 2.1 pints (pt) 1 fluid ounce (fl oz) = 30 milliliters (ml) 1 liter (l) = 1.06 quarts (qt) 1 cup (c) = 0.24 liter (l) 1 liter (l) = 0.26 gallon (gal) 1 pint (pt) = 0.47 liter (l) 1 quart (qt) = 0.96 liter (l) 1 gallon (gal) = 3.8 liters (l) 1 cubic foot (cu ft, ft3) = 0.03 cubic meter (m3) 1 cubic meter (m3) = 36 cubic feet (cu ft, ft3) 1 cubic yard (cu yd, yd3) = 0.76 cubic meter (m3) 1 cubic meter (m3) = 1.3 cubic yards (cu yd, yd3) TEMPERATURE (EXACT) TEMPERATURE (EXACT) [(x-32)(5/9)] °F = y °C [(9/5) y + 32] °C = x °F QUICK INCH - CENTIMETER LENGTH CONVERSION 0 1 2 3 4 5 Inches Centimeters 0 1 2 3 4 5 6 987 1110 1312 QUICK FAHRENHEIT - CELSIUS TEMPERATURE CONVERSIO °F -40° -22° -4° 14° 32° 50° 68° 86° 104° 122° 140° 158° 176° 194° 212° °C -40° -30° -20° -10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° For more exact and or other conversion factors, see NIST Miscellaneous Publication 286, Units of Weights and Measures. Price $2.50 SD Catalog No. C13 10286 Updated 6/17/98 iv Contents Executive Summary ........................................................................................................................ 1 1 Introduction ............................................................................................................................. 3 1.1 Background ..................................................................................................................... 3 1.2 Objectives ....................................................................................................................... 3 1.3 Overall Approach ............................................................................................................ 3 1.4 Organization of the Report .............................................................................................. 3 2 Wireless Sensor Network System Description ....................................................................... 4 2.1 Ad Hoc Mesh Network ................................................................................................... 4 3 System Architecture ................................................................................................................ 9 3.1 General System Layout ................................................................................................... 9 3.2 Overall Mote Architecture ............................................................................................ 10 3.3 Inter-Mote Interfaces .................................................................................................... 12 3.4 Mote Activity State Machine ........................................................................................ 12 3.5 Role of Witronix Wi-PU ............................................................................................... 15 3.6 Role of the Enterprise ................................................................................................... 16 3.7 Addressing .................................................................................................................... 16 3.8 Message Handling ......................................................................................................... 20 3.9 Interface Mitigation ...................................................................................................... 21 3.10 Material Interface .......................................................................................................... 21 4 Wireless Train Network System Hardware .......................................................................... 22 4.1 Microcontroller ............................................................................................................. 22 4.2 IEEE 802-11 WiFi Module ........................................................................................... 23 4.3 Network Hardware
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