Serial Port to Serial Port SwitchSerial Port to Serial Port Switch Design team May03-11

Abstract:Abstract:

This project requires the design of a new serial port switching matrix to replace a This project requires the design of a new serial port switching matrix to replace a current installment; specifically to design, build and test a switching solution that current installment; specifically to design, build and test a switching solution that will be used as a backup to Union Pacific's main system. The system is used to will be used as a backup to Union Pacific's main system. The system is used to control connections to remote sites that monitor train movement, control and verify control connections to remote sites that monitor train movement, control and verify settings of track switches and indicators. The main goal is to find or design the settings of track switches and indicators. The main goal is to find or design the hardware to physically connect the serial modems to the centralized track hardware to physically connect the serial modems to the centralized track controller (CTC) and design software to control the data switch matrix. The controller (CTC) and design software to control the data switch matrix. The system ensures connections to the CTC without user intervention. It is crucial that system ensures connections to the CTC without user intervention. It is crucial that communications with remote sites are maintainable and by routing data through communications with remote sites are maintainable and by routing data through this control matrix, information will get to its destination with little or no human this control matrix, information will get to its destination with little or no human intervention. intervention.

Acknowledgement:Acknowledgement:

Thanks to Gerry Mann and Rick McCormick for their guidance and Union Pacific for Thanks to Gerry Mann and Rick McCormick for their guidance and Union Pacific for financial support.financial support.

General background:General background:

Union Pacific is in need of an automated system that connects and routes Union Pacific is in need of an automated system that connects and routes information traffic with little user input as a backup to their primary system.information traffic with little user input as a backup to their primary system.

Technical problem:Technical problem:

The problem we are solving is to replace a set of switch matrixes with a new design The problem we are solving is to replace a set of switch matrixes with a new design that incorporates new functionality and easier expandability. The current system that incorporates new functionality and easier expandability. The current system that Union Pacific is using is based on hardware switching matrixes that are limited that Union Pacific is using is based on hardware switching matrixes that are limited in their functionality. The problem is reduced mainly to a software problem by using in their functionality. The problem is reduced mainly to a software problem by using off the shelf USB to 16 port RS-232 serial devices and writing custom software to off the shelf USB to 16 port RS-232 serial devices and writing custom software to handle all switching, routing and user interface requirements that Union Pacific handle all switching, routing and user interface requirements that Union Pacific desires. desires.

Operating environment:Operating environment:

The system runs indoors in a climate-controlled room near the CTC. This is an The system runs indoors in a climate-controlled room near the CTC. This is an ideal environment for the system. There is little or no risk of problems related to ideal environment for the system. There is little or no risk of problems related to temperature, moisture, or any other elements that may disrupt the system.temperature, moisture, or any other elements that may disrupt the system.

Intended users and uses:Intended users and uses:

Users:Users: The users shall be educated Union Pacific employees with moderate computer The users shall be educated Union Pacific employees with moderate computer skills. There shall be 3 levels of security allowing administrators to perform skills. There shall be 3 levels of security allowing administrators to perform operations that the general users are not allowed to perform. The administrators operations that the general users are not allowed to perform. The administrators have more knowledge of the system.have more knowledge of the system.

Uses:Uses: The system shall be used as a backup system; it is not intended to handle the The system shall be used as a backup system; it is not intended to handle the entire load of the system for long durations of time, but will be capable if entire load of the system for long durations of time, but will be capable if unforeseen problems occur.unforeseen problems occur.

Assumptions:Assumptions:•The system shall replace the current systemThe system shall replace the current system•Union Pacific will be requiring 30 modem connections at the present timeUnion Pacific will be requiring 30 modem connections at the present time•System needs to be expandable in the future with minimal system changeSystem needs to be expandable in the future with minimal system change

Limitations:Limitations:•The system will be using RS-232 serial port connections and settingsThe system will be using RS-232 serial port connections and settings•The system must connect to existing modemsThe system must connect to existing modems•The system must connect with the CTC as their current system doesThe system must connect with the CTC as their current system does

Assumptions and limitations:Assumptions and limitations:

Design objectives:Design objectives:•One computer to connect COM ports via USBOne computer to connect COM ports via USB•As many external RS-232 connections as required by Union Pacific As many external RS-232 connections as required by Union Pacific •Software to route information from modems to CTC Software to route information from modems to CTC

Functional requirements:Functional requirements:

Design constraints:Design constraints:

The system must interface with existing modems and CTC processor. Union Pacific has already established a way to communicate between the remote sites and a central location. The switch must take the existing modems and connect them to the CTC.

•Pass information from remote sites to the CTC for data collection and controlPass information from remote sites to the CTC for data collection and control•One to many connections- scalable to 256 connectionsOne to many connections- scalable to 256 connections•Software must auto-redial connections without user input in case of disconnectionSoftware must auto-redial connections without user input in case of disconnection•RS-232 interface, must be compatible with currently installed modemsRS-232 interface, must be compatible with currently installed modems•Configurable RS-232 settings and asynchronous speedsConfigurable RS-232 settings and asynchronous speeds

Measurable milestones:Measurable milestones:

•Finalize product description with Union PacificFinalize product description with Union Pacific•Develop a design architecture Develop a design architecture •Acquire hardware and assemble systemAcquire hardware and assemble system•Develop software systemDevelop software system•Test software with hardwareTest software with hardware•Integrate with Union Pacific’s systemIntegrate with Union Pacific’s system

End-Product description:End-Product description:

The scalable RS-232 serial data matrix switch shall be capable of connecting at The scalable RS-232 serial data matrix switch shall be capable of connecting at least 256 serial connections to a centralized controller, with individually configured least 256 serial connections to a centralized controller, with individually configured ports. The matrix switch shall connect any number of serial connections, but in ports. The matrix switch shall connect any number of serial connections, but in this case has been tailored to meet the needs of Union Pacific. The controller will this case has been tailored to meet the needs of Union Pacific. The controller will be used as a backup system to send data between a CTC and remote systems via be used as a backup system to send data between a CTC and remote systems via modem.modem.

Technical Approach:Technical Approach:

The selected approach is to use USB-to-RS-232 The selected approach is to use USB-to-RS-232 hardware in conjunction with a single laptop hardware in conjunction with a single laptop computer running custom switching software to computer running custom switching software to control all of the routing and configurations of the control all of the routing and configurations of the serial ports. This approach offers more advantages serial ports. This approach offers more advantages than disadvantages. The system itself would be easy than disadvantages. The system itself would be easy to set up, requiring only enough USB devices to to set up, requiring only enough USB devices to support the total number of serial ports required. support the total number of serial ports required. This has implications for expandability, as well – with This has implications for expandability, as well – with properly developed control software, adding serial properly developed control software, adding serial ports would be as simple as purchasing more USB ports would be as simple as purchasing more USB devices. These devices are relatively inexpensive, devices. These devices are relatively inexpensive, offering yet another advantage. A disadvantage offering yet another advantage. A disadvantage associated with this design is the complexity of the associated with this design is the complexity of the control software that will be required to maintain the control software that will be required to maintain the matrix of ports/devices. matrix of ports/devices.

Testing Approach:Testing Approach:

•Test USB-Serial Devices and determine scope of interface software to be writtenTest USB-Serial Devices and determine scope of interface software to be written•Write interface software and test against CTC to confirm that communications can Write interface software and test against CTC to confirm that communications can take placetake place

•Testing each generation of software with one, then expanding to many port Testing each generation of software with one, then expanding to many port connectionsconnections

•Build support for required number of ports as well as specific requirements Build support for required number of ports as well as specific requirements provided by Union Pacificprovided by Union Pacific

•Completed system will be field tested against normal use cases and scenariosCompleted system will be field tested against normal use cases and scenarios

Personnel Effort:Personnel Effort:

0 20 40 60

Hours

Brian Hof

Connor Reynolds

Michael Clement

Jason Gordon

Final report

Implementation

Design report

Poster

Project plan

Dr. Doug JacobsonMichael ClementJason GordonBrian HofConnor Reynolds

Faculty AdvisorCPR ECPR ECPR ECPR E

010110010110111101110101001000000110000101100001001000000110111001100101011100100110010000101110011100100110010100100000

Omaha, NEOmaha, NE

Budget:Budget:

ItemItem CostCost

PosterPoster $60$60

Control PCControl PC $1200$1200

USB Serial CardsUSB Serial Cards $1200$1200

TotalTotal $2460$2460