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 50 minutes, x slides • Family Tree, System Overview • System Components • CAD Models/Drawings • Component Assembly Plans • Schematics, Pseudo-Code • Bill of Materials • Feasibility Analysis, Prototyping, and Experimentation 30 mins, x slides • Testing for critical components • Test Plans 5 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 coloured 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. Backpack Assembly • Shell • Cut and assemble main compartment zipper to length. • Apply Liquid Nails to inside edges of top shell • Attach and clamp fully zipped zipper to shell following the instructions of the Liquid Nails • Wait for glue to fully cure • Safety pin unglued zipper side to soft backpack back • Unzip zipper • Sew second half of zipper to soft back • Cut and assemble bottom compartment zipper to length • Apply Liquid Nails to one connection corner of both shell halves • Attach only the starting section the zipper following 3-4 • Attach the rest of the zipper using non-permanent method. • Using a paintmarker or sharpie make marks on shell/zipper in 1in increments (these will be used to make sure zipper and shell are lined up properly when adhering). • Unzip sections • Remove zipper from both sections and clean off non-permanent adhesive • Attach zippers halves to each shell section separately following 2-4. • Unzip • Apply Liquid Nails to back edge of bottom shell section. • Attach and clamp bottom fabric backpack flap to back edge of shell following 3-4. • Attach quick access panel following 9-18. • LEDs • Drill Wire holes in all light strip slots. • Place LED light strips in their appropriate slots with proper adhesive. • For each light signal slot line lens ridge with silicone sealer. • Press each lens into their appropriate slot. • Wipe off any excess sealer and allow to dry • Electronics Pouch, Easy Access Pouch and Other • Place adhesive on edges of neoprene pouch. • Press pouch into the top surface of the bottom backpack compartment. • Allow to dry. • For easy access pouch follow 25-27; except the easy access pouch will be attach on the inside perimeter of the easy access panel. • Drill hole on the bottom right side of shell in appropriate location for power switch. • Apply sealer to edge of hole. • Pop power switch into hole and hold. • Wipe off any excess sealer and allow to dry. • Drill hole in the bottom of the shell for the power cord. • Drill hole in specified location on top access panel for light sensor. • Place light sensor in through the shell. • Apply sealant to back of the sensor to hold in place. • Allow to dry. • Disconnect chest strap clip from strap. • Slide user control panel onto strap. • Reconnect chest strap clip. • Wire all components. • Battery Health Panel: • Press fit PCB into top panel • Apply silicone sealer to back • Fit back panel against the top • Clamp and allow to dry for appropriate time

18. 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

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

20. 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)

21. 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

22. Electronics Housing

23. Electronics Housing Assembly Components • Main Housing • Base (Aluminum) • Long side (on battery side, straight, 2 holes tapped on top) • Long side (dividing board and battery, has slot for wires) • Long side (battery side, has 5 holes (2x DB9, I USB 2x 2-in-1) and 2 holes tapped on top) • 2x Short side (identical, each has slot in the top) • Top piece • 4 screws • Glue Assembly Use mill to dimension pieces to specified dimensions Create required holes (tapped and for plug) Glue long sides and short sides to base as detailed in assembly drawing Add board, with bushings underneath Install board with screws Install top with screws

24. Transmitter Box 24 • Original plans were to fabricate a custom-sized waterproof box for the transmitter • Availability and competitive prices of prefabricated boxes outweigh the benefits of a custom box • Selected box: HAMMOND Plastic Instrument Enclosures Black Project Box Pictured: Bottom (facing up and down) Complete box Price: $4.49 (free shipping)

25. 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

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

27. Cord Retraction • In order to prevent the charging cable from being caught in the rear wheel if disconnected, a retraction system is necessary. • Original plans resembled a retractable dog leash, but because of the size and stiffness of the wire this idea was abandoned. • Rather than have the wire wind up, it will be an extendable coiled wire with the male and female ends being the connectors.

28. 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

29. Cost analysis of Quick-Connect options 29 Choice: Guitar Amp Connector Reasons: -Quicker to attach because of no directional preference - “Clicks” in, less likely to come off accidentally

30. 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 Sel • 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

31. 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

32. 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

33. 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

34. 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

35. 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

36. Battery Health Monitor/Charging Circuit Function • Monitor Internal Battery Voltage • Send Low Bat signal to µCon at desired level • Isolate Internal Battery from system under the following conditions. • Low Battery Level • Connected to: Wall Charger or Bike Power

37. Battery Health Monitor DesignDesign • Compare the voltage on the supply to a reference voltage. • Divide voltage supply level by 3. • Use a 6.2V 1% precision Zener diode to set reference. • Use voltage divider resistor string to set reference voltage levels.

38. Battery Monitor/Charging Schematic Comparators 1% Precision Zener Diode Low-Battery Flag to µCon

39. Power SupplySelection Criteria / Design • Power Supply selection criteria: • Low power dissipation. • Low heat generation. • 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. • Power Supply Design • Vin >10V, 5V Switching Regulator, designed using Manu. Datasheet. • 3.3V Linear Regulator using input from 5V Switching Reg.

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

41. USB Charger Selection Criteria /Design • USB Charger Selection criteria: • Meet requirement of Standard USB Dedicated Charging Port • Maximize charging rate, while minimizing power/time. • USB Charger Design • IC Solution for a Dedicated Charging port. • 1A Charging Current

42. USB Charger Schematic Dedicated Charging Port Controller USB Enable from µCon

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

44. Light Sensor Schematic

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

46. LED Driver Schematic

47. 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

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

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

50. Microcontroller and Rx Schematic Xbee Receiver µController w/ JTAG Prog. Outputs to Light Drivers