Page 7 - July 2024 News On 7

HASTINGS AND PRINCE EDWARD DISTRICT SCHOOL BOARD
HARNESSING THE POWER OF PLAY: ENGAGING PLC STUDENTS WITH
A VEHICLE SIMULATOR
Students in Belleville, Ontario, Canada, have found a way to combine their
passion for video games with the industrial controls coursework they are
studying at the Centennial Secondary School. The team of 11th and 12th year
students was guided by their instructor; John Harpell, an electronics and
automation controls veteran with thirty years of experience.

The result of this effort was the creation of a vehicle simulator, similar to the
“full motion race simulator”, or “racing cockpits” that are commercially
available for gamers and race car drivers alike. The difference here: the fully
gimbaled motion platform (with car seat) was designed and built by the
students, and is controlled by pneumatic actuators and an industrial PLC.
The “driver” sitting in the seat operates a USB-connected steering wheel and
pedal cluster sourced from the video game world. The USB signals for the
steering and pedal action are fed to both the PC that controls the on-screen
visuals, AND to the PLC, which controls the ‘pitch’ and ‘roll’ of the seat, to give the rider/driver realistic feedback of
acceleration, braking and the lateral g-forces of various vehicle maneuvers.
The Leap into the Unknown
One of the biggest challenges of the project that Harpell and his students faced was identifying and interfacing the USB
signals to the PLC. This required not only an understanding of PLC controls but also a deep dive into the mechanics of
USB gaming interaction.
The control system uses a pair of C-more touch panel HMIs connected to a CLICK PLC from Automation Direct.
Numerous momentary, toggle and e-stop buttons are employed along with a key switch for critical and safety functions.
The prime movers for the motion platform are a pair of large pneumatic cylinders (12-inch stroke) which are controlled
by the PLC via 4-way directional control valves.
Note: For the student’s safety, most of the control components are powered by 24 volts. A large 24 volt Rhino DC power
supply is the only AC powered device in the system. Harpell specified the Rhino specifically for it’s built-in foldback
protection with auto recovery.
Crafting the Simulator: A Tale of Innovation and Collaboration
The project required careful planning and execution. The students designed a robust frame capable of supporting the
combined weight of the cockpit, a student and a car seat—approximately 400 lbs in total. Under Harpell’s guidance,
students welded and machined parts to create a steel frame that promised both stability and flexibility. The simulator’s
realistic movements were achieved through the use of automotive suspension techniques and components, to provide a
realistic driving experience.
Engineering the Experience: Safety, Engagement and Learning
The development of the simulator demanded not only technical skills but also a focus on safety. To ensuring that the
simulator was safe, the team focused many discussions on protective measures. Safety solutions included meticulous
inspections for sharp edges, enclosing potential pinch points like coil springs and pneumatic shocks, and implementing
key controls for adult supervision. Additionally, the use of rubber boots over coil springs and an emergency stop function
were crucial in addressing safety concerns while simulating the dynamic movements of a car.
Student engagement was at the heart of this project, with classmates actively participating in the assembly and setup,
contributing valuable insights into software choices and hardware upgrades. This hands-on approach deepened their
understanding of the technical aspects and fostered a sense of ownership and pride in their work.
A Startling Reality: The Dangers of Distracted Driving
A key educational aspect of the simulator was its role in highlighting the dangers of distracted driving. By simulating real-
world scenarios, students experienced firsthand the potentially devastating consequences of taking their eyes off the
road, even for mere seconds. This component of the project served as powerful learning, driving home the importance of
road safety.
The Final Reflection: A Project of Passion and Progress
This project exemplified the potential of combining traditional educational methodologies
with the video game experiences that engage the students. Hopefully it will encourage other
educators to reimagine the boundaries of learning, proving that with passion,
creativity and collaboration, the possibilities are limitless.