Detailed Design Review P13265 Motorcycle Safety Light Backpack System

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Detailed Design Review P13265 Motorcycle Safety Light Backpack System. February 15 th , 2013 RIT MSDI. MSD Team. Primary Customers: Sport bike/standard riders who ride with backpacks Surrogate Customers: Aaron League Andrew Nauss Faculty Guides: Leo Farnand Vince Burolla
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Detailed Design ReviewP13265Motorcycle Safety Light Backpack SystemFebruary 15th, 2013RIT MSDIMSD 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
  • 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
  • I. OVERVIEWProject 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
  • 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
  • Updated Engineering SpecsUpdated Engineering SpecsBorrowed 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 EN500II. SYSTEM MODEL DESIGNPhysical System OverviewBackpackBrake/Running LightsUser Control Panel On Chest StrapAmbient Light SensorTurn SignalsSystem Power SwitchElectronics Box Inside Bottom Backpack CompartmentMotorcycle Power ConnectorPhysical System OverviewMotorcycleWireless Light-Signals OutTransmitter BoxPower OutBike Light Signals InBike Power In(Inside Box)Transmitter Board w/ Xbee TransmitterFamily Tree (1/3)ContinuedFamily Tree (2/3)From Backpack AssemblyContinuedFamily Tree (3/3)From Backpack AssemblyBackpack ShellShell FrontShell BackShell DrawingLightsSelection
  • 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 StripLightsFlash Functionality1st stage brake lights2nd stage brake lightsUpper Large ArrowsUpper Small ArrowsDual Brightness Running/Brake LightsLower Small ArrowsLightsRequirementsPurchase:1 RED strip2 AMBER strips*Note: Decision made to eliminate front shoulder strap lights due to installation complexity and marginal benefit to rider (headlight is much brighter)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 acrylicElectronics HousingChest Strap User Control PanelStatus LED On/OffHazard ButtonLight Pattern SelectBrake/Turn Signal Function ToggleStatus LEDsControl Panel (w/ Cover)Control Panel (Cover Off)View of Attachment LoopChest Strap User Control PanelControl Panel TopControl Panel BottomQuick-Connect Selection CriteriaMust attach and detach both quickly and easilyMust not shake looseMust have reasonable detaching pull force in order to prevent damage to other systems (if rider forgets to unplug)Aesthetically pleasingLow production costCost analysis of Quick-Connect options25Choice: Guitar Amp ConnectorReasons: -Quicker to attach because of no directional preference - “Clicks” in, less likely to come off accidentallySystem Block DiagramBackpackAC/DC12VDCSystem Block DiagramElectronics Housing/PCBMotorcycle SystemMotorcycle Battery12VDCUSB ChargerUSB 2.0System NiMH Battery12VDC2.5mm Connector12V5VQuick ConnectTransmitter Housing/PCBBattery Monitor / FusesVoltage Regulation12V->5V5V->3.3V12V12V12V2.1mm Connector3.3VPower Switch12V->3.3V Regulation1µCon (MSP430)XbeeReceiver12VDarlingtonLight DriversXbee Transmitter234Calibrate Button31245678Chest Strap Signals1-4. Battery Status LEDs
  • Function Toggle
  • Function Toggle Select
  • Hazard
  • 3.3V
  • Transmitter Signals
  • Headlight
  • Left Turn Signal
  • Right Turn Signal
  • Brake Light
  • 12 LED GroupsChest Strap PCBUser Interface ButtonsBattery Status LEDsBattery 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
  • 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
  • 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
  • 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
  • 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
  • Battery Monitor/Charging SchematicComparatorsLow-Battery Flag to µConPower 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.
  • Power Supply Schematic5V Switching Regulator3.3V Linear RegulatorUSB Charger SelectionCriteria
  • USB Charger Selection criteria:
  • Meet requirement of Standard USB Dedicated Charging Port
  • Maximize charging rate, while minimizing power/time.
  • USB Charger SchematicUSB Enable from µConLight Sensor SelectionCriteria
  • Light Sensor selection criteria:
  • QSD124 NPN Silicon Phototransistor
  • Narrow Reception Angle of 24DEG
  • Power Dissipation is Max 100 mW
  • Light Sensor SchematicLED Driver Selection
  • Drive a # of 3-LED segments requiring 200mA/segment.
  • Switch on/off using a µController input signal
  • 0V->3.3V
  • LED Driver SchematicWireless 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
  • Xbee CodeConfigures the TX unit+++-Grabs unit attentionATRE-ResetsATID 2286-Sets addressATMY 1-Sets my address to 1ATD0 3ATD1 3ATD2 3ATD3 3-Sets DIO 0 through 3 to digital inputATDH 0-Sets destination address highATDL 2-Sets destination address of receiverATIR 14-Sets sample rate to 20msATPR 0-Disables internal pull-upsATWR-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
  • Transmitter (Tx) Board SchematicInputsVoltage RegulationTransmitterBike SignalsMicrocontroller SelectionCriteria
  • Microcontroller selection criteria:
  • Minimize controller power consumption.
  • Maximize # of I/Os.
  • Have PWM functionality.
  • Microcontroller and Rx SchematicXbee ReceiverµControllerOutputs to Light DriversChest 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
  • Chest Strap SchematicPseudo-CodePseudo-CodeContinued from aboveOverall Bill of MaterialsOverall Bill of MaterialsHigh Cost ItemsShell Mold Fabrication- $135 w/shippingBattery- $66 w/shippingLights- $53 w/shippingXbee Units- $38Microcontroller Dev. Kit- $29PCBs- Unknown at this pointIII. FEASIBILITY ANALYSIS, PROTOTYPING & EXPERIMENATIONLight SystemLuminosity Test
  • Three tests completed:
  • LED florescent tube strip (benchmark)
  • 4.4W 30 LED high power strip
  • 1.1 W 30 LED water resistant strip
  • Tested high-brightness and weatherproof light strips in daylight
  • Observed brightness ~100 ft away from light
  • All strips bright enough during day
  • Illuminated Light Strip*Note: Strip was much brighter than picture showsResults: Lights bright enough for requirementsLight SystemPower Consumption CalculationsResults: With very conservative estimate, in worst-case scenario, system should operate from battery for >2 hoursBike Mock-UpTransmitter Box
  • A mock-up for transmitter placement was completed on donor bike
  • Test-fit laptop charger into inner cover
  • Dimensions are 1.75 x 4 x 1 inch (H x L x W)
  • Charger fit within cover with extra room
  • Transmitter box will be much smaller than charger => fits
  • Inner cover is protected from elements from outer cover (not pictured)
  • Results: Good location determined for Tx boxCharger1.75”1”4”Inner CoverTransmitter Box57
  • 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 3”x 2”x 1”
  • Pictured: Bottom (facing up and down)Complete boxPrice: $4.49 (free shipping)Bike Mock-UpBike Battery Power Wire Routing
  • Proper routing of the wire from the 12V bike battery is very important for several reasons:
  • Mitigation of any risk that wire can catch on rider
  • If wire detaches, should not create safety risk (i.e. catch in chain/wheel)
  • With wire attached, rider should be able to move freely
  • Rider should be able to easily attach wire
  • Considered several routing options:
  • 1. In front of seat
  • 2. Rear of seat
  • 3. Side of seat
  • # 1# 3# 2Bike Mock-UpBike Battery Power Wire Routing: Option 1
  • Option 1 quickly eliminated due to routing over rider’s legs
  • Safety and rider discomfort issues
  • Bike Mock-UpBike Battery Power Wire Routing: Option 2
  • Option 2 is possible, but not ideal
  • Space under seat for wire to route without any stress concerns
  • However, wire would have to route over seat, which could blow around in wind and create greater risk of detachment
  • Bike Mock-UpBike Battery Power Wire Routing: Option 3Results: Option 3 is best method
  • Option 3 presents best routing method
  • No interference with rider
  • No stresses/ methods for damage to wire
  • Shortest wire length of 3 options
  • Space between frame and chromeMock-up Wire Routed with Seat onIV. SYSTEM ASSEMBLY & TEST PLANSSystems Assembly
  • 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
  • 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 paint marker 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
  • V. NEXT STEPSUpdated Risk Assessment (1/3)Updated Risk Assessment (2/3)Updated Risk Assessment (3/3)MSD II Plan- OverviewMSD II Plan- OverviewMSD II Plan- 4 week plan
  • End Week 1
  • Complete Final Assembly and Test Plans- All
  • End Week 2
  • Completed Assembly of Transmitter Housing- Ben
  • Completed Assembly of Transmitter Board- TJ
  • Completed Debugging of Transmitter Housing- TJ
  • End Week 3
  • Completed Assembly of In-bag Electronics Assembly- Ben
  • Completed In-bag Assembly Board- Eric/ TJ
  • Completed Backpack External Shell- Tyler/ Mike
  • Completed DC Quick Connect Assembly- Ben
  • End Week 4
  • Completed Backpack Shell Integration w/Soft Shell- Tyler
  • Completed Light/Light Cover Integration w/Shell- Mike/ Tyler
  • Completed Debugging of In-Bag Assembly- Eric/ TJ
  • VI. CONCLUSION, COMMENTSQuestions
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