modelrail.otenko trains….

An attempt to simulate Acceleration and Braking

In my previous post, I'd managed to get my Densha-De-Go Dreamcast controller hooked up to my Arduino Mega. Now although this now meant that I had a great way to control my model railroad, it also meant I had to work out how to code a throttle and a brake lever.

The rules

After a few hours of plotting, I had decided on the following system. It involves a 6-position throttle and an 11-position brake. Each 'position' is to have a 'max speed' and 'speed adjust' associated with it.

Notes

• It is to be assumed that if the brake is on, the throttle is automatically disabled
• MAX is 255 on the PWM Throttle (or max voltage from supply)
• At Throttle 0, the train is neither powering nor braking; we will simply slowly decrement the speed
• There is no feedback to know how fast the train is currently travelling
• There are multiple emergency brake points on the throttle, but we don't care about them.

The next table shows my acceleration and braking deltas. This will be a simple addition and subtraction on the current speed.

Lever position	Max Speed	Speed Adjustment
Emergency Full		Instant Stop
Emergency 5		-50
Emergency 4		-30
Emergency 3		-25
Emergency 2		-20
Emergency 1		-10
Brake 9		-2.4
Brake 8		-1.8
Brake 7		-1.2
Brake 6		-0.8
Brake 5		-0.4
Brake 4		-0.2
Brake 3		-0.1
Brake 2		-0.05
Brake 1		-0.025
Throttle 0	0	0.00
Throttle 1	55	+0.25
Throttle 2	75	+0.5
Throttle 3	90	+1
Throttle 4	100	+1.75
Throttle 5	120	+2.5

And now a better way to represent it.

The code

The table above translates to code quite easily... the goal is to have the lever position values coded into an array and then just select the correct entry. Once determined, the main code loop can then determine how to adjust the current voltage output to the rails.

const int throttle_positions = 21;
const int throttle_absolute_maximum_speed = 255;
const int throttle_minimum_speed = 20;
int current_throttle_position = -1; // 0 is EM FULL. Lever must be moved to EM FULL to begin.
float current_speed = 0;
float target_speed = 0;
int throttle_max_speed[throttle_positions] =  {
	0,0,0,0,0,0,0,0,0,0,0,0,0,0,0, //brake positions and Throttle 0
	0, 55, 75, 90, 100, 120
};
float throttle_delta[throttle_positions] = 	{
	0.025, 0.05, 0.1, 0.2, 0.4, 0.8, 1.2, 1.8, 2.4, 10, 20, 25, 30, 50, 9999, //brake
	0.00 /*coast*/, 0.25, 0.5, 1, 1.75, 2.5
};

We then need to determine the current throttle position. We will make it that, at the start of code execution, the train should not move until the throttle has been reset to EM Full and the throttle at '0'.

#define BRAKE_MASK 0xf0
#define BRAKE_SHIFT 4
#define ACCEL_MASK 0x07
void read_throttle_position() {
	int accel = packet.data[6] & ACCEL_MASK;
	int brake = (int)((packet.data[7] & BRAKE_MASK) >> BRAKE_SHIFT);

	if (current_throttle_position == -1) {
		//check that we have EM FULL and Neutral
		if (brake  == 15 && accel  == 1) {
			//set the initial '0' (EM FULL) position.
			current_throttle_position = 0;
			lcd.clear();
		}
	} else {
		if (brake != 1) { //1 == "BRAKE 1", if it's higher, we're braking.
			if (brake > 0) current_throttle_position = brake;
		} else { //BRAKE == 1 and then we check the throttle
			//we're accelerating.
			if ((accel + 15) < 22) current_throttle_position = accel + 15;
		}
	}
}

And now the main game loop needs to determine the current lever locations and then choose the appropriate action:

void update_speed() {
		digitalWrite(13, LOW);
	//make sure we are allowed to go.
	if (current_throttle_position >= 0) {
		if (current_speed > throttle_max_speed[current_throttle_position - 1]) {
			current_speed -= throttle_delta[current_throttle_position - 1];

			//braking... don't go negative.
			if (current_speed < throttle_minimum_speed)
				current_speed = 0; 

		} else if (current_speed < throttle_max_speed[current_throttle_position - 1]) {

			//accelerating, so start from minimum speed.
			if (current_speed < throttle_minimum_speed)
				current_speed = throttle_minimum_speed;

			current_speed += throttle_delta[current_throttle_position - 1];

			//don't go faster than current throttle max setting.
			if (current_speed > throttle_max_speed[current_throttle_position - 1])
				current_speed = throttle_max_speed[current_throttle_position - 1];
		}

		//set light if we have met max speed for throttle.
		if (current_speed == throttle_max_speed[current_throttle_position - 1])
			digitalWrite(13, HIGH);

		//output speed to railway.
		analogWrite(7, current_speed);
	} else {
		//flash the LED to alert user to reset controls.
		delay(200); //delay a little to flash the LED
		digitalWrite(13, HIGH);
		delay(200);
	}
}

There's also some code in the main loop to update the 16x2 LCD I've hooked up. Since we need to reset the controller when we start, it'll tell you to do so and afterwards will tell you the current throttle/brake position, current speed and speed delta.

Action shots

Shown is the controller in certain positions. Note that the 'Throttle' positions may show a negative speed delta; this just means that they are no longer accelerating.

Arduino + Dreamcast Densha-De-Go Controller

I've had Densha-De-Go and the controller for the Dreamcast for a while now... I'd even invested a few hours in playing the actual game, but the accuracy required is crazy. Supposedly in Japan it's that realistic that even real train drivers have a hard time getting it spot on

Anyway, I'd wanted to get this going for train control for a while after managing to make a Wii Nunchuck control my trains.

You can find more information on the controller at SEGA Retro, SEGAGAGA Domain, Wikipedia, Play Asia and genki Video Games.

Previous attempts

Quite a few months ago I spent a few hours with my Densha-De-Go controller and my Arduino Mega in an attempt to get them to communicate. The goal was to be able to read the controller and then use it to control my model railroad. Unfortunately, I was doing this blind, running off information from Marcus Comstedt's 'Dreamcast Programming' site; specifically his breakdown of the Maple Bus Protocol.

I ended up with nothing working and sent out a few pleas for help on the Arduino forum and to Marcus himself. I received information regarding the fact that it should work (the Arduino had the horsepower), but I would have to ensure the timing was intricate and that the Arduino was always ready to receive data.

I then posted to the Arduino Forum for help. A few months later WzDD came to my rescue with word that he had successfully made the Arduino communicate with a Dreamcast Controller. I hadn't had much time up until now to work on this, and WzDD hadn't done any further work on it, so I took it that he just wanted to prove the concept and that I'd have to get off my backside to make things progress further. In the end, I did want to get my controller functioning.

I had previously had everything I needed to test this again, so I gave it another go. My previous setup was a cut-in-half Dreamcast controller extension cable and my Densha-De-Go controller. The extension cable meant I didn't have to hack around with the actual controller or port imitation.

Getting set up...

Due to the requirement to use assembler for the actual low-level controller interactions, we cannot use the Arduino IDE and must use WinAVR (or just avrdude on Linux.) Download this from here (select the latest version) and install to the default directory.

You then need to download the arduino-maple source code and extract somewhere locally. I've put the folder on C:\arduino-maple\.
Open Programmers Notepad [WinAVR] from the start menu and then open the arduino-maple.cpp file from where it has been extracted. (C:\arduino-maple\arduino-maple.cpp in my case.)
If all is installed correctly, then you should be able to choose Tools - [WinAVR] Make All and have the following output in the output window:

> "make.exe" all
avr-gcc -Wall -g2 -gstabs -Os -fpack-struct -fshort-enums -ffunction-sections -fdata-sections -ffreestanding -funsigned-char -funsigned-bitfields -mmcu=atmega328p -DF_CPU=16000000UL -I./arduino -c arduino/pins_arduino.c -o build/arduino/pins_arduino.o
In file included from arduino/wiring_private.h:30,
                 from arduino/pins_arduino.c:26:
c:/winavr-20100110/lib/gcc/../../avr/include/avr/delay.h:36:2: warning: #warning "This file has been moved to <util/delay.h>."
...
Lots of warnings, no errors...
...
avr-g++ -Os -Wl,-gc-sections -mmcu=atmega328p  build/arduino/pins_arduino.o build/arduino/WInterrupts.o build/arduino/wiring.o build/arduino/wiring_analog.o build/arduino/wiring_digital.o build/arduino/wiring_pulse.o build/arduino/wiring_shift.o build/./arduino-maple.o build/arduino/HardwareSerial.o build/arduino/Print.o build/arduino/Tone.o build/arduino/WMath.o build/arduino/WString.o build/./libmaple.o -o app.elf
avr-objcopy -R .eeprom -O ihex app.elf  app.hex
avr-size --format=avr --mcu=atmega328p app.elf
AVR Memory Usage
----------------
Device: atmega328p

Program:    3380 bytes (10.3% Full)
(.text + .data + .bootloader)

Data:        796 bytes (38.9% Full)
(.data + .bss + .noinit)

> Process Exit Code: 0
> Time Taken: 00:02

Now, as you can see above... that's not my Arduino! I have an Arduino Mega and therefore we need to adjust the Makefile correctly for my setup. Here you'll need to know the CPU code, interface type and the port number. Also make sure you change the upload task to program so that we can use the menu items in WinAVR.

# Makefile for building small AVR executables, supports C and C++ code
# Author: Kiril Zyapkov
# Hacked up by nfd

SOURCE_DIRS = . arduino
INCLUDE_DIRS = arduino
MMCU = atmega1280
F_CPU = 16000000UL
SRC_ROOT = .
BUILD_DIR = build

CFLAGS = -Wall -g2 -gstabs -Os -fpack-struct -fshort-enums -ffunction-sections \
 -fdata-sections -ffreestanding -funsigned-char -funsigned-bitfields \
 -mmcu=$(MMCU) -DF_CPU=$(F_CPU) $(INCLUDE_DIRS:%=-I$(SRC_ROOT)/%)

CXXFLAGS = -Wall -g2 -gstabs -Os -fpack-struct -fshort-enums -ffunction-sections \
 -fdata-sections -ffreestanding -funsigned-char -funsigned-bitfields \
 -fno-exceptions -mmcu=$(MMCU) -DF_CPU=$(F_CPU) $(INCLUDE_DIRS:%=-I$(SRC_ROOT)/%)

LDFLAGS = -Os -Wl,-gc-sections -mmcu=$(MMCU) #-Wl,--relax

TARGET = $(notdir $(realpath $(SRC_ROOT)))
CC = avr-gcc
CXX = avr-g++
OBJCOPY = avr-objcopy
OBJDUMP = avr-objdump
AR  = avr-ar
SIZE = avr-size

SRC = $(wildcard $(SOURCE_DIRS:%=$(SRC_ROOT)/%/*.c))

CXXSRC = $(wildcard $(SOURCE_DIRS:%=$(SRC_ROOT)/%/*.cpp))

ASMSRC = $(wildcard $(SOURCE_DIRS:%=$(SRC_ROOT)/%/*.S))

OBJ = $(SRC:$(SRC_ROOT)/%.c=$(BUILD_DIR)/%.o) $(CXXSRC:$(SRC_ROOT)/%.cpp=$(BUILD_DIR)/%.o) $(ASMSRC:$(SRC_ROOT)/%.S=$(BUILD_DIR)/%.o)

DEPS = $(OBJ:%.o=%.d)

$(BUILD_DIR)/%.o: $(SRC_ROOT)/%.c
	$(CC) $(CFLAGS) -c $< -o $@

$(BUILD_DIR)/%.o: $(SRC_ROOT)/%.S
	$(CC) $(CFLAGS) -c $< -o $@

$(BUILD_DIR)/%.o: $(SRC_ROOT)/%.cpp
	$(CXX) $(CXXFLAGS) -c $< -o $@

all: app.hex printsize

#$(TARGET).a: $(OBJ)
#	$(AR) rcs $(TARGET).a $?

app.elf: $(OBJ)
	$(CXX) $(LDFLAGS) $(OBJ) -o $@

$(BUILD_DIR)/%.d: $(SRC_ROOT)/%.c
	mkdir -p $(dir $@)
	$(CC) $(CFLAGS) -MM -MF $@ $<

$(BUILD_DIR)/%.d: $(SRC_ROOT)/%.cpp
	mkdir -p $(dir $@)
	$(CXX) $(CXXFLAGS) -MM -MF $@ $<

#$(TARGET).elf: $(TARGET).a
#	$(CXX) $(LDFLAGS) $< -o $@

app.hex: app.elf
	$(OBJCOPY) -R .eeprom -O ihex $<  $@

clean:
	echo $(RM) $(DEPS) $(OBJ) $(TARGET).*

printsize:
	avr-size --format=avr --mcu=$(MMCU) app.elf

# Programming support using avrdude. Settings and variables.
PORT = /dev/tty.usbserial-A700ekGi
#PORT = /dev/ttyUSB0
AVRDUDE_PORT = com3
AVRDUDE_WRITE_FLASH = -U flash:w:app.hex
MCU = atmega1280
AVRDUDE_PROGRAMMER = stk500v1
#AVRDUDE_FLAGS = -V -F -C \app\arduino-0021\hardware\tools\avr\etc\avrdude.conf
AVRDUDE_FLAGS = -V -F \
-p $(MCU) -P $(AVRDUDE_PORT) -c $(AVRDUDE_PROGRAMMER) \
-b $(UPLOAD_RATE)
UPLOAD_RATE = 57600
#
# Program the device.
INSTALL_DIR = \app\arduino-0021
AVRDUDE = avrdude
program: app.hex
	#python pulsedtr.py $(PORT)
	$(AVRDUDE) $(AVRDUDE_FLAGS) $(AVRDUDE_WRITE_FLASH)

The first line in the program target (Line 93) 'pushes' the reset button on the Arduino. As we don't have Python installed we have to do this manually. So, build the source code via the [WinAVR] Make All and ensure there are no errors. Now press the 'reset' button on the Arduino and then quickly choose Tools - [WinAVR] Program. If all goes correctly then you'll see the code uploading to your Arduino:

#python pulsedtr.py /dev/tty.usbserial-A700ekGi
avrdude -V -F -p atmega1280 -P com3 -c stk500v1 -b 57600 -U flash:w:app.hex
avrdude: AVR device initialized and ready to accept instructions

Reading | ################################################## | 100% 0.05s

avrdude: Device signature = 0x1e9703
avrdude: NOTE: FLASH memory has been specified, an erase cycle will be performed
         To disable this feature, specify the -D option.
avrdude: erasing chip
avrdude: reading input file "app.hex"
avrdude: input file app.hex auto detected as Intel Hex
avrdude: writing flash (3508 bytes):

Writing | ################################################## | 100% 1.09s

avrdude: 3508 bytes of flash written
avrdude done.  Thank you.

> Process Exit Code: 0
> Time Taken: 00:03

And that's it, our the compiled code for the arduino-maple project is now on the Arduino and running!

Using the Python code on Windows

I lied, I said I didn't have Python installed... but I ended up installing it anyway. The job to convert the Python code to C# was going to take too long and, to prevent a debugging nightmare, I decided I would get the known-to-work Python code going under Windows first. So, I installed Python from the official website and then started learning

Note that I downloaded and installed Python Version 2.6.6 as this was the version that would have been available when arduino-maple was created.

After selecting 'IDLE' from the start menu, I was presented with a light-weight GUI. I opened up the 'maple.py' that's included with the arduino-maple code and attempted to compile it.

I had problems at the start, as in the included Makefile there are two declarations of CPU type. Initially I hadn't set these both correctly and the Arduino includes were not correctly compiled... make sure you carry out a proper clean whenever changing code; this includes manually deleting all of the .o files.

Once this was sorted, it all finally worked... sort of?

connecting to COM3:
connected
SENT: 0000200121
No device found at address:
0x20
SENT: 0000010100
1c20000501000000ff0f3f000000000000000000415400ff204f544920313030746e6f436c6c6f7
2202072652020202020200024191bdc94191958dd481e508815481c9bdc99591b98da5308195
cdb995bdc91881154c8c9b40481051d491551394d25494130b14d1480b911508080808007d00371 117
Command 5 sender 0 recipient 20 length 1c
Device information:
Functions  : CONTROLLER
Periph 1   : 0x3f0fff
Periph 2   : 0x0
Periph 3   : 0x0
Name       : ..TAITO 001 Controller      $.
License    : .....X...P.H..H..Y...S....\....[..T.....Q.I.I%M9M.0A.......P
Power      : 53251
Power max  : 32775
Play with the controller. Hit ctrl-c when done.
SENT: 010020090100000029
SENT: 010020090100000029
1111101010011111
SENT: 010020090100000029
1111101010011111
SENT: 010020090100000029
1111101010011111
SENT: 010020090100000029
1111101010011111

Timing issues

As I continued to run the code, I would get random results as to the 'Name', 'License' and 'Power' fields... well, it was obvious in the text fields that there were problems, but I had no idea that what the 'Power' fields were meant to read. Either way, this indicated a timing issue somewhere and I guessed that life was about to get difficult. Note that I had always been running the controller at 5v, as that's what WzDD's post said the blue wire should be connected to, but it turns out that the device should have actually been running on 3.3v.

Unfortunately, setting the controller on to 3.3v didn't change anything... the responses were still mildly random. The buttons would be sent though correctly (apart from the B button) but the initial device description would come through jumbled. I took a few samples of the data and realised that the data would always have a minimal length. To me this meant that we weren't missing bytes/bits, but actually reading too many. The analysis showed that there were similar chunks all the way through, but at certain intervals there'd be extra/changed characters. Based on Marcus Comstedt's Maple Bus information, I guessed that we were re-reading bits too quickly and needed to slow down a little... This would mean slowing down the pin reading in WzDD's arduino-maple assembler code.

In the maple_rx_raw: function down near _rx_loop:, the code iterates through the pins hoping to read the data. It initially checks the state of the pins to sense when the controller is about to send data, but this did not have the final check for the second pin going low.

4:	IN rport2, _SFR_IO_ADDR(PINB)
	BST rport2, bitmaple5			; maple5
	BRTS 4b							; must be low now

The above code was added around line 305 to ensure this check was in. I then also 'spaced' out the store/read calls by placing a delay in. WzDD had already written the delayquarter macro and I simply re-used this.

	...
	_rx_store rport bitmaple5 5
	_rx_read bitmaple5
	delayquarter
	_rx_store rport bitmaple1 4
	_rx_read bitmaple1
	...

After these two changes, the text from the device information call worked flawlessly. But my B button still didn't work. I decided the B button wasn't important at this stage and went on to decoding the controller to work out how the levers functioned.

Densha-De-Go controller workings

So, after having used the standard Dreamcast controller to play hours-upon-hours of Shenmue, Shenmue II and Chu chu rocket, I would have expected at least one of the levers on the Densha-De-Go controller to use the analog joystick and the other to also use some form of analog control. After a few minutes decoding the controls, it became apparent that they simply used the buttons available (up, down, left, right, x, y, z) in a binary-value style configuration.

In between the B's there is a slight overlap of the buttons, where the current and next 'combination' is combined, but this doesn't seem to last more than one cycle.
In between the EM's the controller reads UP-DOWN-LEFT-RIGHT. This area exists between all EM's and B8-EM0 and seems to be about 3mm wide.

Controlling trains

Now it was time to get this incorporated into my original train throttle. I didn't want to have to use the Python code, so instead I 'crafted' the packets into the Arduino code.

	//here is a quick packet to request device information from controller 'one'.
	//i.e. the only controller connected.
	packet.header[0] = 0; // Number of additional words in frame
	packet.header[1] = 0; // Sender address = Dreamcast
	packet.header[2] = (1 << 5); //(1 << 5); // Recipient address = main peripheral on port 0
	packet.header[3] = 1; // Command = request device information
	packet.data[0]   = 0x21; //checksum
	packet.data_len  = 5;
	//send the above packet to initiate comms with the controller.
	maple_transact();

I'm going to gloss over this part pretty quickly, as this post was more about getting the Dreamcast controller usable rather than another lesson in physics and model railway throttles. For the code, I ended up just deciphering the packet that comes back from the controller, working out what the throttle position is and then adjusting the target speed. The main program loop then makes then increment/decrements the current speed to eventually match the target speed. This provides a very simple form of acceleration.

void control_throttle(void) {
	//quick hack, should actually do a binary 'and'
	//packet data[6] contains the throttle position, so use this to gauge
	//voltage output to pin 7 (or speed)
	switch (packet.data[6]) {
		case 0xF9: target_speed = 0;	t_pos = 0; break;
		case 0xFA: target_speed = 88;	t_pos = 1; break;
		case 0xFB: target_speed = 96;	t_pos = 2; break;
		case 0xFC: target_speed = 140;	t_pos = 3; break;
		case 0xFD: target_speed = 190;	t_pos = 4; break;
		case 0xFE: target_speed = 250;	t_pos = 5; break;
	}
}

The changing of pin 13 below lights the on-board Arduino LED to show once the loop has made the speed match the target speed.

	digitalWrite(13, LOW);
	if (target_speed > speed) {
		//accel
		speed += t_pos / 2;
	} else if (target_speed < speed) {
		//speed += abs(target_speed - speed);
		//decel
		speed--;
	} else {
		digitalWrite(13, HIGH);
	}
	//send the speed to the pin/railway
	analogWrite(7, speed);

And then... it just worked

As you can see, I've only implemented the throttle on the controller... I need to now bring in the brake lever as well, but this is where the physics lesson comes in. I'll be posting again soon enough with source code for acceleration and braking using this controller.

I've got a few ideas as to how to semi-realistically control the train with both levers, but I will need to do a little more reading before I get something going. I do know that in the actual Densha-De-Go game, the game complains when you have both levers on at the same time... and it seems wrong to be doing so... but then again, it'd be like doing a hill-start Maybe for freight trains?

If only our model railway trains had gears and could free roll!

Sending full bytes over .NET Serial Ports to the Arduino

Ok, I have just spent a good two nights of my life diagnosing why I could sent all bytes up to value '127' and no further. In hindsight, it all makes perfect sense and the documentation is clear, but when you've been taught to think in strings, you might hit this very quickly.

The Scenario

I have my MAX7219 + LedControl Library set up on my Arduino and all works fine. I use two functions to control it: setLed and setRow. setLed simply takes a boolean to determine if the LED you are pointing at is to be on or off, but setRow requires a byte. This is all fairly straight-forward as each 'row' in the LED matrix has 8 LEDs, and a byte has 8 bits. So, starting from the lowest significant bit, a value of b00000001 will turn on the first LED in a specified row. (i.e. setRow(DEVICE,ROW,BITS);).

All communications between my application and the Arduino had been based on strings and so I had previously been using one character (one byte) to set one LED. Due to this being a complete waste of bandwidth, I decided that each byte I sent through the channel should be a byte to control full row of LEDs. This meant that I could therefore no longer 'see' the output as a string (or ASCII), as the characters I would create from setting the bits may no longer be in ASCII range... this was no big deal, as I could just view the byte values and decode it all myself.

So, on the client end (C#.NET Application) I started encoding the bytes from bit values. This all worked until I tried to set the last bit...

byte b = 1 | (1 << 7); //let's set the first and last LED.
string buffer = (char)b + "\0";
serialPort.WriteLine(buffer);

Data Sent	LEDs lit	Correct?
b00000001	1st	OK
b01010101	1st, 3rd, 5th, 7th	OK
b10101010	1st, 2nd, 3rd, 4th, 5th, 6th	WRONG
b10000001	1st, 2nd, 3rd, 4th, 5th, 6th	WRONG
b01000000	7th	OK
b10000000	1st, 2nd, 3rd, 4th, 5th, 6th	WRONG

What the hell was going on?

The Answer

So, after reading numerous blogs and not finding my answer, I went to the Arduino Forums and posted a topic asking for help. I was given advice to write a very simple test app to work out where the bytes were failing... but I never did get to write that app, instead I went to the MSDN site as soon as I saw that the Write() procedure could be overloaded.

And look what I found at the article on MSDN:

By default, SerialPort uses ASCIIEncoding to encode the characters. ASCIIEncoding encodes all characters greater then 127 as (char)63 or '?'. To support additional characters in that range, set Encoding to UTF8Encoding, UTF32Encoding, or UnicodeEncoding.

And guess what... ASCII Character ? is 63 in decimal and therefore b00111111 in binary!
So, whenever I was setting the 8th bit, the .NET Framework (in all it's wisdom) would translate this to a question mark as it was not expecting to send an invalid ASCII character. Ladies and Gentlemen, ASCII is only 7 bits!

The work-around?

byte[] b = new [] { 1, 127, 128, 129, 255 }; //let's set the first bit, last bit, etc...
serialPort.WriteLine(b, 0, b.Length);

And then everything just worked.

 read value of detector
 if (detector value is greater than recorded maximum) then record new maximum value
 if (detector value is lower than recorded minimum) then record new minimum value
 if (either min or max has changed)
  then update range of this detector [max - min]
  adjust threshold [max - (range*0.25)]
 end if
 if (detector value is greater than threshold) then
  report that this detector is 'active'
 else
  report that this detector is 'inactive'
 end if

 store the last 32 values of detector in circular array
 read value of detector and push last into array, popping off the first value
 find the lowest value in the array and store as the minimum extremity
 find the highest value in the array and store as the maximum extremity
 if (either min or max has changed)
  then update range of this detector [max - min]
  calculate the average from the last 32 read values
  adjust threshold [average + (max-min*0.10)]
 end if
 if (detector value is greater than this threshold) then
  report that this detector is 'active'
 else
  report that this detector is 'inactive'
 end if

class DetectorCollection {
	private:
		struct Detector {
			int dValues[32];
			int dMax;
			int dMin;
			int dRange;
			int dAverageValue;
			int dCurrentValue;
			int dThreshold;
			int dCurrentIndex;
			bool dFullArray;
			int dAnalogPin;
			int dBitIndex;
			bool dIsActive;
		} detectors[32];
		int numDetectors;
		int digPins[3];
	public:
        DetectorCollection(int _digPin1, int _digPin2, int _digPin3);
        bool AddDetector(int _aPin, int _bit);
        void UpdateDetector(int detector);
        void UpdateAllDetectors();
        bool IsActive(int detector);
        void DebugInformation(int detector);
        int GetCurrentValue(int detector);
};

DetectorCollection::DetectorCollection(int _digPin1, int _digPin2, int _digPin3) {
	numDetectors = 0;
	digPins[0] = _digPin1;
	digPins[1] = _digPin2;
	digPins[2] = _digPin3;
}

bool DetectorCollection::AddDetector(int _aPin, int _bit) {
	//initialise a detector. the array contains "zero'd" detectors
	//by default
	if (numDetectors < 32) {
		detectors[numDetectors].dAnalogPin = _aPin;
		detectors[numDetectors].dBitIndex = _bit;
		for (int idx = 0; idx < 32; idx++)
			detectors[numDetectors].dValues[idx] = 0;
		detectors[numDetectors].dMax = 0;
		detectors[numDetectors].dMin = 999;
		detectors[numDetectors].dRange = 0;
		detectors[numDetectors].dAverageValue = 0;
		detectors[numDetectors].dThreshold = 0;
		detectors[numDetectors].dCurrentIndex = 0;
		detectors[numDetectors].dFullArray = false;
		detectors[numDetectors].dIsActive = false;
		numDetectors++;
		return true;
	} else return false;
}

void DetectorCollection::UpdateDetector(int detector) {
	//set digital pins
    for (int pin = 0; pin < 3; pin++)
      digitalWrite(digPins[pin],
        ((detectors[detector].dBitIndex >> abs(pin-2)) & 0x01) == true ? HIGH : LOW);

	//read analog pin.
	detectors[detector].dCurrentValue =
        analogRead(detectors[detector].dAnalogPin);
	detectors[detector].dValues[detectors[detector].dCurrentIndex] =
        detectors[detector].dCurrentValue;

	//find the lowest and highest values in the array and store as
	//the minimum and maximum extremities.
	int tempVal, newValue = 0;
	bool extremitiesChanged = false;
	for (int idx = 0; idx < 32; idx++) {
		tempVal = detectors[detector].dValues[idx];
		if (tempVal < detectors[detector].dMin || detectors[detector].dMin == 0) {
			detectors[detector].dMin = tempVal;
			extremitiesChanged = true;
		}
		if (tempVal > detectors[detector].dMax) {
			detectors[detector].dMax = tempVal;
			extremitiesChanged = true;
		}
		//used for average calculated below.
		newValue += tempVal;
	}

		//update range of this detector [max - min]
		detectors[detector].dRange =
		    detectors[detector].dMax - detectors[detector].dMin;
		if (newValue > 0) {
			if (detectors[detector].dFullArray)
                          detectors[detector].dAverageValue = newValue / 32;
			else detectors[detector].dAverageValue =
                          newValue / (detectors[detector].dCurrentIndex + 1);
			//adjust threshold [average + (max-min*0.10)]
			detectors[detector].dThreshold =
                          detectors[detector].dAverageValue +
                          (detectors[detector].dRange * 0.35);
			//adjust active flag:
			detectors[detector].dIsActive =
                          (detectors[detector].dCurrentValue >
                           detectors[detector].dThreshold);
		}

	//finally update the next location to store the next incoming value...
	//we're using a circular buffer, so just point to the start of the
	//array instead of shifting everything along.
	detectors[detector].dCurrentIndex++;
	if (detectors[detector].dCurrentIndex >= 32) {
		detectors[detector].dCurrentIndex = 0;
		//for calculating the average, we need to know once
                //we have a full buffer. Once it's full we will always
                //have a full set of NUM_READINGS values, otherwise
		//we only have as many as dCurrentIndex
		detectors[detector].dFullArray = true;
	}
}

void DetectorCollection::UpdateAllDetectors() {
  for (int d = 0; d < numDetectors; d++) UpdateDetector(d);
}

bool DetectorCollection::IsActive(int detector) {
  return detectors[detector].dIsActive;
}

int DetectorCollection::GetCurrentValue(int detector) {
  return detectors[detector].dCurrentValue;
}

void DetectorCollection::DebugInformation(int detector) {
  Serial.print("Detector: ");
  Serial.print(detector);
  Serial.print(", APin: ");
  Serial.print(detectors[detector].dAnalogPin);
  Serial.print(", DBit: ");
  Serial.print(detectors[detector].dBitIndex);
  Serial.print(", Min: ");
  Serial.print(detectors[detector].dMin);
  Serial.print(", Max: ");
  Serial.print(detectors[detector].dMax);
  Serial.print(", Range: ");
  Serial.print(detectors[detector].dRange);
  Serial.print(", Threshold: ");
  Serial.print(detectors[detector].dThreshold);
  Serial.print(", Average: ");
  Serial.print(detectors[detector].dAverageValue);
  Serial.print(", Current: ");
  Serial.print(detectors[detector].dCurrentValue);
  Serial.print(", FullArray: ");
  Serial.print(detectors[detector].dFullArray);
  Serial.print(", CurrentIndex: ");
  Serial.println(detectors[detector].dCurrentIndex);
  /*for (int idx = 0; idx < 32; idx++) {
    Serial.print("|");
    if (idx == detectors[detector].dCurrentIndex) Serial.print("*");
    Serial.print(detectors[detector].dValues[idx]);
  }
  Serial.println("|");*/
}

#define multiplexerPinBitA  40
#define multiplexerPinBitB  41
#define multiplexerPinBitC  42

#define pwmPin  			2
#define dirPin1 			3
#define dirPin2 			4

#define lcdRSPin			30
#define lcdENPin			31
#define lcdD4Pin			32
#define lcdD5Pin			33
#define lcdD6Pin			34
#define lcdD7Pin			35

#include <LiquidCrystal.h>
LiquidCrystal lcd(lcdRSPin, lcdENPin, lcdD4Pin, lcdD5Pin, lcdD6Pin, lcdD7Pin);

//cool hack! create characters for the LiquidCrystal Library!
//see here: http://icontexto.com/charactercreator/
byte trainCharFrontOn[8] =
{B11111,B10001,B10001,B11111,B10101,B11111,B01010,B11111};
byte emptyChar[8] =
{B00000,B00000,B00000,B00000,B00000,B00000,B11111,B10101};

DetectorCollection dCol = DetectorCollection(multiplexerPinBitA,
    multiplexerPinBitB, multiplexerPinBitC);

void setup() {
  Serial.begin(9600);
  pinMode(multiplexerPinBitA, OUTPUT);
  pinMode(multiplexerPinBitB, OUTPUT);
  pinMode(multiplexerPinBitC, OUTPUT);

  for (int d = 0; d < 24; d++) {
    //analogpin is 0, 1, 2 [so DIV 8].
    //(where 0 is detectors 1-8, 1 is 9-16 and 2 is 17-24)
    //bit is the 0-7 on that analog pin [so MOD 8].
    dCol.AddDetector(d/8, d%8);
  }

  //start a train: direction
  digitalWrite(dirPin2, HIGH);
  digitalWrite(dirPin1, LOW);
  //speed (out of 255 [where ~50 is stopped])
  analogWrite(pwmPin, 85);

  lcd.createChar(0, emptyChar);
  lcd.createChar(1, trainCharFrontOn);
  lcd.begin(16, 2);
}

void loop() {
  //output to the LCD (16x2) the status of all the detectors:
  lcd.clear();
  lcd.setCursor(0, 0);	//top left

  for (int d = 0; d < 16; d++) {
    dCol.UpdateDetector(d);
    lcd.write(dCol.IsActive(d) ? 1 : 0);
  }
  lcd.setCursor(8, 0);
  for (int d = 16; d < 25; d++) {
    dCol.UpdateDetector(d);
    lcd.write(dCol.IsActive(d) ? 1 : 0);
  }

  //we still have 8 characters to draw other stuff... no idea what yet though.
  delay(333);
}

Properly reading values from a Sharp GP2D12

Right, my efforts to read an IR Voltage until now have been flawed. It seems that my method of just plugging analogue inputs into my Arduino and expecting a clean reading was pointless. 'Noise' is a huge factor when reading analogue inputs (let alone correct pull-up/down resistors and grounding!) and dirty power supplies + PWM generation circuits really do kill any analogue data floating around.

Before I go into the actual sensors, read the Analogue Input Pin tutorial for the Arduino and also some sample code to read range of Sharp sensor.

So, how do you sort all these noise issues this out? Capacitors!
Based on the references below... you're either to put a ~22uf Capacitor between Vcc and GND or a 4.7uf Capacitor between Vout and GND. Firstly, here's the references:

Arduino + Sharp Sensors:

• Sharp IR Sensor, bad code? *fixed*
• Ir Distance Sensor Probelm
• Linearizing Code for Sharp GP2D120 Infrared Ranger

Other links on the Sharp sensors:

• oIRRange Object
• Electronic Distance Measurement
• Effectively Using the Sharp GP2D12 Rangefinder

From all this information above I tinkered further with the sensors; but then proceeded to give up. The readings were much more stable, but I simply couldn't get them to do what I wanted as their values would drop off when the distance between the vehicle and sensor was less than 10cm.

Following is the code I used. Note that it does some trickery with caching the last 20 values and averaging them... I'll explain this all further in my next post.

//LIBRARY
#define NUM_INDEXES 20
 
class DistanceDetector {
 private:
  int min_valid;
  int max_valid;
  int analogPinNumber;
  int latest_max_value;
  int latest_min_value;
  int latest_time_updated;Here is the code I used anyway
  int lastIndex;
  bool full;
  void CalcAverage();
  
 public:
  int lastReadValues[NUM_INDEXES];
  int sensorValue;
  DistanceDetector(int _analogPinNumber);
  void UpdateDetector();
};
  
  
DistanceDetector::DistanceDetector(int _analogPinNumber) {
 min_valid = 100;
 max_valid = 600;
 lastIndex = 0;
 analogPinNumber = _analogPinNumber;
 full = false;
 for (int idx = 0; idx < NUM_INDEXES; idx++) lastReadValues[idx] = 0;
}
 
void DistanceDetector::UpdateDetector()
{
 int latest_value = analogRead(analogPinNumber);
 if (latest_value >= min_valid && latest_value <= max_valid) {
  lastReadValues[lastIndex] = latest_value;
  CalcAverage();
  lastIndex++;
  if (lastIndex > NUM_INDEXES) {
   lastIndex = 0;
   full = true;
  }
 }
}
 
void DistanceDetector::CalcAverage() {
 sensorValue = 0;
 for (int idx = 0; idx < NUM_INDEXES; idx++) sensorValue += lastReadValues[idx];
 if (sensorValue > 0) {
  if (full) {
   sensorValue /= NUM_INDEXES;
  } else {
   sensorValue /= (lastIndex+1);
  }
 }
}
 
 
//USAGE:
DistanceDetector d1(SENSOR_PIN);
 
void setup() {
 //nothing required, as the constructor takes the pin number.
}
void loop() {
 d1.UpdateDetector(); //update the sensor.
 Serial.println(d1.sensorValue); //print out the value.
}

Conclusion

I still should have bought the GP2D120! But either way, I've decided to go with standard LDR/IR optics in the track base. Sadly, I'm over attempting the distance detection. My next post will cover a less-visible method for occupancy detection in the sleepers.