Detailed Design Review P13265 Motorcycle Safety Light Backpack System

1. Detailed Design ReviewP13265Motorcycle Safety Light Backpack System February 15th, 2013 RIT MSDI

2. MSD Team • Primary Customers: • Sport bike/standard riders who ride with backpacks • Surrogate Customers: • Aaron League • Andrew Nauss • Faculty Guides: • Leo Farnand • Vince Burolla • Industrial Design Consultant: • Killian Castner • Team Members: • Mike Baer, Project Manager • Tyler Davis, Lead Engineer • Ben Shelkey, ME Project Engineer • TJ Binotto, EE Project Engineer • Eric Dixon, EE Project Engineer

3. Today’s Agenda • Overview 5 minutes, 1 slide • Project Description Recap • Borrowed Motorcycle Specs • System Model Design 45 minutes, x slides • Family Tree, System Overview • System Components • ME- CAD Models/Drawings • EE- Schematics, Pseudo-Code • Bill of Materials • Feasibility Analysis, Prototyping, and Experimentation 30 mins, x slides • Testing for critical components • System Assembly and Test Plans 10 mins, x slides • Next Steps 15 mins, x slides • Updated Risk Assessment • MSDII Plan • Conclusion, Comments 15 mins, x slides

4. I. OVERVIEW

5. Project Description Review • This project is intended to be prototype stage for marketable product for motorcyclists: • Two major needs identified by motorcyclists: • 1. Safety • Hurt Report • Motorcyclist safety study performed by Henry Hurt, published in 1981 • Of the accidents analyzed, ~75% of motorcycle accidents involved collision with another vehicle • “Failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of motorcycle accidents” • Motorcycle Conspicuity Study • Riders wearing any reflective or fluorescent clothing had a 37% lower risk than other riders • Conclusion: “Increasing the use of reflective or fluorescent clothing, white or light colored helmets, and daytime headlights…could considerably reduce motorcycle crash related injury and death.” • 2. Electronics charging • Most motorcyclists have no means of charging electronics

6. Project Description Review • Conducted market survey regarding safety equipment and small electronics charging • Currently at 77 participants (for results visit EDGE website) • Summary of target market (motorcyclists who): • Often or always wear backpacks • Carry bulky items, such as books or laptops • Ride in 4 seasons, and wet conditions (rain, fog, snow) • Currently do not have method for charging electronics (such as cell phone) • Micro USB charging connection required • Believe visibility is important • Utilize reflective surfaces, bright colors, and lighting systems • Would consider upgrading their existing lights to LED lights • Place importance of aesthetics and durability of products

7. Updated Engineering Specs

8. Updated Engineering Specs

9. Borrowed Motorcycle • Type: 2006 Kawasaki Vulcan EN500 • Owner: Andrew Nauss, 5th year ME • Gave permission to test on bike and make small modifications, if necessary • Not ideal type of bike for target market, but it shares same engine and electronics with the Ninja 500, a popular entry-level sport bike Vulcan EN500

10. II. SYSTEM MODEL DESIGN

11. Physical System OverviewBackpack Brake/Running Lights User Control Panel On Chest Strap Ambient Light Sensor Turn Signals System Power Switch Electronics Box Inside Bottom Backpack Compartment Motorcycle Power Connector

12. Physical System OverviewMotorcycle Wireless Light-Signals Out Transmitter Box Power Out Bike Light Signals In Bike Power In (Inside Box) Transmitter Board w/ Xbee Transmitter

13. Family Tree (1/3) Continued

14. Family Tree (2/3) From Backpack Assembly Continued

15. Family Tree (3/3) From Backpack Assembly

16. Backpack Shell Shell Front Shell Back Shell Drawing

17. LightsSelection • Lights: • Compared thru-hole vs. flexible strips • Strips proved to be better for application • Colored LEDs documented to be more efficient than using white LED with colored lens cover • Strips available in .5m length w/ 30 LEDs/strip • Can be cut into increments of 3 LEDs • Each 3 LED segment has necessary resistors to operate @ 12V • 3 sets of High Intensity 30 LED SMD Strips • 2 amber and 1 red • $15/ strip, $45 total • *Note: 11 sections of red strips are needed, but only 10/ strip • Will instead use one amber section, but will purchase 2nd red strip in MSDII if budget allows Flexible LED Strip

18. LightsFlash Functionality 1st stage brake lights 2nd stage brake lights Upper Large Arrows Upper Small Arrows Dual Brightness Running/Brake Lights Lower Small Arrows

19. LightsRequirements Purchase: 1 RED strip 2 AMBER strips *Note: Decision made to eliminate front shoulder strap lights due to installation complexity and marginal benefit to rider (headlight is much brighter)

20. Light CoversSelection • Lens Covers: • Provide protection from elements • Clear thermoform acrylic sheets • Can bend to required shape • Clear: • ~92% Light Transmission @ 90 degrees incident to surface • Red and Amber: • ~9-15% Transmission @ 90 degrees • Currently in discussion with manufacturer • Will be sending free samples of both clear and red • Can hold off on purchasing until samples are received • Sheets will be cut to size and molded to sit flush with External Shell • Diffusion Material: • Diffusion material is not necessary and will not be used • Could potentially be added after completion of build Clear acrylic

21. Electronics Housing

22. Chest Strap User Control Panel Status LED On/Off Hazard Button Light Pattern Select Brake/Turn Signal Function Toggle Status LEDs Control Panel (w/ Cover) Control Panel (Cover Off) View of Attachment Loop

23. Chest Strap User Control Panel Control Panel Top Control Panel Bottom

24. Quick-Connect Selection Criteria Must attach and detach both quickly and easily Must not shake loose Must have reasonable detaching pull force in order to prevent damage to other systems (if rider forgets to unplug) Aesthetically pleasing Low production cost

25. Cost analysis of Quick-Connect options 25 Choice: Guitar Amp Connector Reasons: -Quicker to attach because of no directional preference - “Clicks” in, less likely to come off accidentally

26. System Block Diagram Backpack AC/DC 12VDC System Block Diagram Electronics Housing/PCB Motorcycle System Motorcycle Battery 12VDC USB Charger USB 2.0 System NiMH Battery 12VDC 2.5mm Connector 12V 5V Quick Connect Transmitter Housing/PCB Battery Monitor / Fuses Voltage Regulation 12V->5V 5V->3.3V 12V 12V 12V 2.1mm Connector 3.3V Power Switch 12V->3.3V Regulation 1 µCon (MSP430) Xbee Receiver 12V Darlington Light Drivers Xbee Transmitter 2 3 4 Calibrate Button 3 1 2 4 5 6 7 8 Chest Strap Signals 1-4. Battery Status LEDs • Function Toggle • Function Toggle Select • Hazard • 3.3V Transmitter Signals • Headlight • Left Turn Signal • Right Turn Signal • Brake Light 12 LED Groups Chest Strap PCB User Interface Buttons Battery Status LEDs

27. Battery SelectionTechnology • Re-evaluated initial selection of Li-Po battery due to safety concerns • For scope of project, not possible to design box that is guaranteed to prevent any damage to battery in event of crash • Li-Po and Li-Ion battery can catch on fire if cells are damaged, even with no current draw • Decided upon Ni-MH: • They do not catch fire when damaged • Still meet performance requirements • Downside, heavier and larger volume

28. Battery SelectionCriteria • Battery selection criteria: • Meets minimum 12V voltage requirement (from lights) • Meets minimum required power draw • Meets maximum current draw (~3.5A worst-case) • Can be connected to off-the-shelf AC smart charger • Built in overcharge protection and thermal monitoring

29. Battery SelectionComparison • Three options • Selection limited due to required capacity • Selection further limited due to 12V requirement • Total price includes pack, charger • Cost between 3 choices was negligible

30. Battery SelectionComparison • After comparing in PUGH diagram, Powerizer Flat pack/charger was chosen due to flat size and larger capacity for the same price • 4500 mAh, 12V, 4.2A max • Dimensions: 7.2 x 2.9 x .8 inches • Cost: $66, shipped • 5 day lead time before shipping

31. Battery Health Monitor SelectionCriteria • Battery Health Monitor Criteria: • Monitor voltage levels on NiMH Battery (14.5V-10.5V) • Be able to load shed USB charging system at a specific voltage. • Shut off system as safe shutdown (10.5V) • Send signals to Battery Status LEDs on chest strap

32. Battery Monitor/Charging Schematic Comparators Low-Battery Flag to µCon

33. Power Supply SelectionCriteria • Power Supply selection criteria: • Low power dissipation. • Low heat dissipation. • Pass max voltage to Safety Lights • Regulate battery voltage to 5V for USB Charging System • Regulate battery voltage to 3.3V for µCon, Wireless, User Interface switches and Battery Status LEDs.

34. Power Supply Schematic 5V Switching Regulator 3.3V Linear Regulator

35. USB Charger SelectionCriteria • USB Charger Selection criteria: • Meet requirement of Standard USB Dedicated Charging Port • Maximize charging rate, while minimizing power/time.

36. USB Charger Schematic USB Enable from µCon

37. Light Sensor SelectionCriteria • Light Sensor selection criteria: • QSD124 NPN Silicon Phototransistor • Narrow Reception Angle of 24DEG • Power Dissipation is Max 100 mW

38. Light Sensor Schematic

39. LED Driver Selection • Drive a # of 3-LED segments requiring 200mA/segment. • Switch on/off using a µController input signal • 0V->3.3V

40. LED Driver Schematic

41. Wireless Transmission SelectionCriteria • Xbee 802.15.4 Low-Power module w/ PCB Antenna • Little configuration required for RF Communication • Low-Power Consumption • Low Input Voltage (3.3V) and Current (50mA) requirements • Small Physical Size • Large amount of open-source documentation

42. Xbee Code Configures the TX unit +++ -Grabs unit attention ATRE -Resets ATID 2286 -Sets address ATMY 1 -Sets my address to 1 ATD0 3 ATD1 3 ATD2 3 ATD3 3 -Sets DIO 0 through 3 to digital input ATDH 0 -Sets destination address high ATDL 2 -Sets destination address of receiver ATIR 14 -Sets sample rate to 20ms ATPR 0 -Disables internal pull-ups ATWR -Writes to memory • Configures the RX unit • +++ • -Grabs unit attention • ATRE • -Resets • ATID 2286 • -Sets address • ATMY 2 • -Sets my address to 2 • ATD0 5 • ATD1 5 • ATD2 5 • ATD3 5 • -Sets DIO 0 through 3 to digital output • ATIA 1 • -Sets I/O input address to TX address • ATWR • -Writes to memory

43. Transmitter (Tx) Board Schematic Inputs Voltage Regulation Transmitter Bike Signals

44. Microcontroller SelectionCriteria • Microcontroller selection criteria: • Minimize controller power consumption. • Maximize # of I/Os. • Have PWM functionality.

45. Microcontroller and Rx Schematic Xbee Receiver µController Outputs to Light Drivers

46. Chest Strap System SelectionCriteria • Chest Strap criteria: • House User Interface Switches • House Battery Status LEDs • Minimize Power Consumption • Can be connected to off-the-shelf AC smart charger • Built in overcharge protection and thermal monitoring

47. Chest Strap Schematic

48. Pseudo-Code

49. Pseudo-Code Continued from above

50. Overall Bill of Materials