Design Objectives
For an electric train horn to be implemented successfully, certain criteria must be met.
Bidirectional sound
Sound output level (96 - 110)dB from 100 ft.
Efficiency and sustainability
Functional Flow Chart
Step 1
The first step of our design process was power implementation. With a 74 VDC source, we have to power an audio chip as well as our amplifiers. To do this, we are using two DC-DC converters. The first converter will step the power down to 24 V which will power the amplifiers. The second DC-DC converter steps the 24 V down to 5 V which power our audio chip.
74-24 V DC-DC Converter
24-5 V DC-DC Converter
Step 2
The second step of our design process was sound amplification. Our design makes use of two amplifiers in parallel. This helps with the effectiveness and sustainability of the amplifiers. The amplifier design also determines how the four compression drivers are connected. With the total load of the four compression drivers being too low or too high, the amplifiers can function improperly and inefficiently.
Audio Amplifiers
Step 3
The third step of our design was the audio chip. In an effort to keep the design simple, we went with the Adafruit Audio FX sound board. This audio chip requires no code to function, nor does it need an external storage to upload audio files to. With built in storage, we simply name the file we want to play in accordance with whichever pin we want to ground. When the pin is grounded, the sound will be played one time. There are also other naming conventions that can make the sound loop or continue and play other sounds.
Adafruit Audio FX Mini Sound Board
Step 4
The fourth step in our design process was to choose a compression driver that could efficiently meet the sound decibel requirement. Our requirements for a good compression driver were a high-power output and a low load. The compression driver we chose has a 320-Watt maximum output and a total load of 4 ohms.
Compression Driver
Testing and Results
The Federal Railroad Administration requires train horns to be between 96 and 110 decibels from 100 feet. Testing requires six tests to be completed, and the average decibel reading must be within the given range.
Our final prototype came in just under the FRA requirement of 96dB. We believe that, if given more time, we would be able to meet the required sound output level with minimal impact to the horns design or cost.